PMB Performance Project Spotlight
Stock Looks, Modern StoppingUpgrading Our 1962 VW Beetle with EMPI Zero Offset Disc Brakes Our 1962 Volkswagen Beetle looks remarkably close to the car that left the factory more than six decades ago. Under the engine lid, however, it is an entirely different story. The Beetle’s extremely healthy RedE 2109cc engine provides far more power, and considerably more speed, than Volkswagen’s engineers anticipated when they designed the original drum-brake system. We recently renewed the drum brakes with new components, and they function as intended. Nevertheless, operating a high-powered vintage Beetle in modern traffic can still be, to put it politely, interesting. |
Ten feet away it still reads as factory, with Wide-5 wheels on all four corners. |
Behind the lid, a RedE 2109cc with dual carburetors — considerably more engine than Volkswagen was designing brakes for in 1962. |
The issue is not simply how quickly the car can stop once. It is the confidence, consistency and control required to drive alongside modern vehicles at today’s road speeds. A braking system that was adequate for a stock early-1960s Beetle is being asked to manage a substantially more capable car. Our solution is a four-wheel EMPI Zero Offset disc brake conversion that will preserve the Beetle’s stock appearance while bringing its braking performance into much closer alignment with its engine performance. |
The Goal: Improve the Car Without Changing Its Character
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This project is not about building a visibly modified Volkswagen. We want the Beetle to retain:
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The original drums were recently renewed and still work as designed. The upgrade is about matching the braking system to the Beetle’s 2109cc engine and the demands of modern traffic. |
What we do not want to retain is the uncertainty that can accompany four-wheel drum brakes when a lightweight Beetle is powered by a strong 2109cc engine.
That makes EMPI’s Zero Offset brake system particularly appealing. Rather than forcing us to change the car’s wheels, widen its track or install conspicuously modern components, these kits are designed to provide disc-brake performance while retaining the early Volkswagen 5x205mm Wide-5 wheel pattern.
To most observers, the finished Beetle should still look completely stock. The meaningful changes will be hidden behind the wheels, and immediately apparent from the driver’s seat.
Zero Offset in one photograph: the rotor’s hub sits where the drum’s did, so the original Wide-5 wheels bolt straight on without adapters. |
The Front ConversionFor the front of the car, we will install the EMPI Zero Offset Front Disc Brake Kit for Link-Pin cars with a dual master cylinder, part number 22-2879-0. |
This kit is designed for 1954–1965 Type 1 Beetles and Karmann Ghias equipped with stock-style drum-brake spindles. EMPI uses a specially designed rotor and caliper mounting bracket to produce near-zero offset, allowing the original Wide-5 5x205mm wheels to be retained without adapters or a meaningful loss of tire clearance.
The front kit includes:
- Disc brake rotors with 12x1.5mm threaded wheel mounting holes
- Brake calipers and pads
- Caliper mounting brackets
- A dual-circuit master cylinder
- OE-style flexible brake hoses
- Wheel bearings and grease seals
- Dust caps
- Installation hardware and instructions
The front kit, part 22-2879-0: caliper in gold zinc, pads, the caliper mounting bracket, the dual-circuit master cylinder, OE-style flexible hoses, and the rotor seen in profile beside the original drum.
The kit is engineered to work with the Beetle’s existing stock-height link-pin spindles. That is important because we are not trying to lower the car or alter its stance. We simply want to replace the front drums with a properly engineered disc-brake system while keeping the rest of the front suspension configuration intact.
EMPI specifies that this kit must be used with 15-inch wheels. Before final assembly, wheel-to-caliper clearance, wheel backspacing, tire clearance and lug-bolt engagement must all be verified. EMPI’s brake catalog specifically cautions installers to confirm these dimensions rather than assuming that every wheel-and-tire combination will clear a conversion kit.
Why the Dual-Circuit Master Cylinder MattersThe inclusion of a dual-circuit master cylinder is an important part of this conversion. Our Beetle was originally designed around an early single-circuit hydraulic system. In a single-circuit arrangement, the front and rear brakes share one hydraulic circuit. A major fluid leak or hydraulic failure can potentially affect braking at all four wheels. |
The new dual-circuit unit above the Beetle’s original single-circuit cylinder. Two circuits mean one hydraulic failure no longer affects all four wheels. |
A dual-circuit master cylinder separates the front and rear portions of the hydraulic system. Should one circuit lose pressure, the other circuit can continue to provide some braking ability. It is not a substitute for proper inspection or maintenance, but it adds an important level of redundancy to a street-driven vintage car.
For a project centered on safety rather than appearance alone, the master-cylinder upgrade is every bit as significant as replacing the drums with discs.
Hub and disc in a single casting, which is what removes the need for a wheel adapter and keeps the 5x205mm Wide-5 pattern. |
The Rear ConversionAt the rear, we will use the EMPI Zero Offset Rear Disc Brake Kit for Swing-Axle cars with an emergency brake, part number 22-2905-0. This system fits 1958–1967 Type 1 Beetles and Karmann Ghias and retains the early 5x205mm Wide-5 wheel pattern. Its one-piece rotor design eliminates the need for wheel adapters and provides a straightforward path from the original rear drums to rear disc brakes. |
The rear kit includes:
- One-piece disc brake rotors with 12x1.5mm threads
- Brake calipers and pads
- Caliper mounting brackets
- Emergency-brake cables
- OE-style flexible brake hoses
- Installation hardware and required gaskets
The rear kit, part 22-2905-0: caliper with its integrated emergency-brake arm and return spring, pads, the mounting bracket and gasket plate, and OE-style flexible hoses.
Retaining a functional mechanical parking brake is essential on a street car. EMPI offers some rear brake configurations without emergency-brake provisions for specialized competition use, but those are not the appropriate choice for this Beetle. Our objective is a complete, practical street system, not a race-only arrangement.
The Zero Offset rear kit also allows us to retain the original track width and stock-looking Wide-5 wheels. Combined with the front conversion, the result should be a Beetle that reveals virtually nothing about its upgraded braking system until the brake pedal is applied.
Installation by an ASE Certified TechnicianThe complete front-and-rear conversion will be performed by PMB Performance ASE Certified Technician Wayne Lashlee. Wayne’s installation will include inspection and verification of the surrounding systems, including:
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ASE Certified Technician Wayne Lashlee fitting a Wide-5 wheel. |
The system will then be checked for leaks, interference and correct operation before the vehicle is road-tested.
This is safety-critical work. EMPI states that the installer is responsible for determining whether the components are suitable for the specific vehicle and warns that improperly installed or maintained brakes are dangerous. The company also recommends seeking qualified assistance when there is any uncertainty about installation.
The completed front: EMPI rotor and caliper on the stock link-pin spindle. No drop and no widened track. |
Why Disc Brakes?Properly adjusted drum brakes can work well on a stock vintage Volkswagen. This project is not an argument that every drum-brake Beetle is inherently unsafe. Our car, however, is no longer stock in the area that places the greatest demand on the brakes. A 2109cc engine can bring a Beetle to speed much more quickly than its original engine. Modern traffic also demands more frequent speed changes, higher sustained road speeds and a greater ability to react to vehicles equipped with modern braking systems. |
Disc brakes offer several practical advantages for this application:
More consistent braking
Disc brakes are generally less sensitive to heat buildup than enclosed drums. Their exposed rotors can release heat more effectively, helping maintain a more consistent response during repeated stops.
Better wet-weather recovery
Water can remain trapped inside a drum assembly. An exposed disc and pad arrangement can clear moisture more readily once the brakes are applied.
Easier inspection
Pad thickness, rotor condition, hose routing and many aspects of caliper operation are easier to inspect without disassembling a complete drum-brake assembly.
No routine shoe adjustment
Drum systems depend on correct shoe adjustment. Disc calipers automatically compensate for normal pad wear as the pistons move outward.
Greater confidence
The most important improvement may be the driver’s confidence in the car. Predictable pedal response and consistent braking allow the driver to concentrate on traffic and vehicle placement rather than constantly planning around the limitations of an older braking system.
We will reserve final judgment until the system is installed, properly bedded and tested. The objective is not to publish an unsupported stopping-distance claim. It is to create a balanced package in which the brakes, engine, tires and chassis work together more appropriately.
EMPI at 70: A History of Making Volkswagens Better
This installation is especially timely because 2026 marks the 70th anniversary of Joe Vittone’s original EMPI. EMPI traces its origins to 1956 and the Volkswagen work of Vittone and Economotors in Riverside, California.
From its earliest days, EMPI understood a principle that remains relevant to our Beetle: faster Volkswagens require better brakes.
EMPI’s 2025 brake catalog explains that Joe Vittone learned this through competition ranging from the Baja Peninsula to road racing and drag racing. More powerful engines were only part of the equation. Reliable, robust braking allowed the cars to be driven faster with greater confidence and safety.
That philosophy has developed into one of the broadest disc-brake conversion programs in the classic Volkswagen market. EMPI states that its brake catalog contains more than 100 unique kits designed, engineered and tested in Anaheim, California. The company evaluates brake components on its own test vehicles to verify fit and performance before offering them through its dealer network.
Seventy years after the company’s beginnings, EMPI continues to support the full range of air-cooled Volkswagen owners: restorers, daily drivers, custom builders, off-road enthusiasts and racers.
The Zero Offset system represents the kind of product that has made EMPI so important to the VW community. It solves a thoroughly modern problem without asking the owner to discard the visual identity of the original car.
The rear, finished. With a wheel back on, none of it shows. |
A Safety Upgrade That Respects the Original VolkswagenVintage-car modifications often require compromise. More performance can mean less originality. Better handling can mean a visibly altered stance. Larger brakes can require modern wheels that dramatically change the appearance of the car. This conversion is different. |
Our 1962 Beetle will retain its stock body, stock suspension configuration and Wide-5 wheels. It will still look like an early Beetle because it is an early Beetle. The EMPI system simply gives the chassis a more appropriate braking system for the power it now produces and the roads on which it is driven.
For owners who regularly use their vintage Volkswagens, this may be one of the most worthwhile safety-first modifications available.
A Beetle, Karmann Ghia, Bus or Thing should still feel like a vintage Volkswagen. It should also stop confidently enough to be enjoyed in modern traffic. With EMPI’s extensive selection of application-specific disc-brake systems, owners can choose a conversion that fits their model, suspension, wheel pattern and intended use.
Stock looks. More consistent braking. Greater confidence. That is exactly what we want from this project.
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Make Your Vintage VW Stop as Well as It Goes
Explore EMPI disc-brake conversion kits for classic Volkswagen Beetles, Super Beetles, Karmann Ghias, Buses and Things. Choose from Wide-5, 4x130mm, Porsche-pattern, stock-height, drop-spindle, zero-offset and high-performance configurations.