Next installment, Harrop Brakes, very brief this time;
As mentioned in my initial write up, I went on a pretty big mission to fix persistent brake shudder. This has been an issue in all Falcons from BA onward.
EF and EL falcons didn't have the issue as long as we ran factory rotors. Interestingly aftermarket rotors on EF/EL developed brake shudder over about 5,000-7,000 km. Machine the rotors and they would be OK for another 5,000 - 7,000 km and begin shuddering again.
My experience with EF/EL falcons was that the factory rotors were quite soft and wore very quickly, I remember the pads wearing into the rotors and raising lips on the outer edges of the rotors say 2mm high. Stock pads were lasting around 20,000km and rotors maybe 40,000km, this said there was never a shudder issue. Aftermarket rotors were a lot harder and lasted much longer but suffered from shudder.
The EF/EL experience contributed to my suspicion that the rotor type (harder) played a key role in the issues seen in BA onward. The BA's were getting front pad life of up to 70,000km and rotor life well in excess of this. The rotors on BA's were not wearing out due to wear they were going undersize due to being machined numerous times to correct shudder.
I sat on the fence for a while after trying two sets of DBA rotors and disc machining of the stock rotors along with different pad types, none of this fixed the issue for more than 7,000km. Finally I sprung for Harrop brakes, funny story about this, the car was a novated lease through work at the time (hence all the stealthy easily reversible modifications) so I managed to get the lease company to pay for the Harrop upgrade by calling it a repair, sure it was my own money but it was pre-tax at least.
History aside, here is a shot of the LH front brake assembly, note the Kmac caster camber kits are installed in the background, also two allen head bolts through the chassis rail just above the caliper are holding the process west surge tank and 044 set up, still running the Bilstein shocks and Kings spring set up at this time. For the super observant out there you may notice the top left Kmac adjuster is at maximum adjustment outward (pushing the top ball joint rearward for maximum caster) while the RH adjuster is set to whatever it needed to be to get to -1.2 degrees camber.