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All Terrain Series - Standard Size Brake Discs

Benefits at a glance

  • Reduced stopping distances in both wet and dry conditions.
  • Substantially reduced brake fade during emergency stops.
  • Improved brake consistency when performing numerous consecutive brake applications (e.g. When descending mountain passes).
  • Excellent brake modulation in wet, muddy and sandy conditions, particularly when modulation is required at the very slow speeds encountered under technical off-road driving conditions.
  • Improved disc and pad life on heavy 4x4 vehicles.


Our All Terrain disc design is the result of an intensive test and development program. The design shares many features with our well known fast-road and race discs but has unique benefits in off-road conditions. The discs feature a moderate, curved slot pattern machined into the friction faces of the disc. In cross-section, the slots are wider and feature a larger radius, when compared to the parallel walls of the narrower slots on our GT Series disc design. The result is that the dirt and mud that may be encountered in off-road conditions is far less likely to clog up the slots and reduce brake efficiency.

Our All Terrain discs are directional and the curved slots are designed to move debris such as sand, mud, water and ‘dead’ pad material to the outside diameter of the disc. The slots run out at the edge of the disc to allow for this debris to be efficiently expelled from the disc / pad interface. The result is excellent brake consistency in wet, sandy or muddy conditions. Serious off-road enthusiasts will really appreciate this attention to detail when driving heavy off-road conditions!

Of course 4x4 / SUV owners tend to drive long stretches of open road in order to get to their off-road destinations. Often these vast open spaces are covered at considerable speed in vehicles that are heavily loaded with passengers, luggage, accessories, fuel and water. It is also common for 4x4 owners to substantially increase their vehicle’s power outputs. This additional weight and horsepower places substantial additional strain on the vehicle’s stock brake components and can result in dangerous brake fade when braking from high speeds or during heavy repetitive braking down mountain passes etc.

One of the predominant causes of brake fade on heavy 4x4 vehicles is friction gasses that form when pad bonding agents burn up and turn to gas at high disc temperatures. These gases can form a barrier layer between the disc and pad, hereby reducing brake efficiency. The slots machined into the pad track area of our All Terrain discs act as gas relief pathways that efficiently channel away friction gasses resulting in substantially reduced brake fade.

Powerbrake All Terrain series discs are cast from a proprietary cast-iron alloy that offers improved wear life and excellent friction levels. We machine or All Terrain discs to extremely tight tolerances (up to three times tighter than the industry norm). Every single disc is measured for run out and disc thickness variation (DTV) prior to leaving our factory. We will not ship a disc with a run out value greater than 0.03mm or a DTV value greater than 0.005mm. This 100% measuring policy is extremely rare in the industry and insures every single disc that we ship is perfect in terms of dimensional accuracy when it leaves our factory. Other unique features include: Max Temperature Recording paints (for easy monitoring of maximum disc temperatures), visual wear indicators (for quick easy inspection of disc wear), dynamic balancing, proprietary dry coating (ensuring quick bed-in and max friction co-efficient) and a specially designed ‘wide’, spiral slot pattern (which is offset inboard/outboard to reduce unwanted harmonics under braking).

Consider that the brake system on your 4x4 converts the momentum of the vehicle into heat during the braking process. The two variables that influence how much heat is generated under braking are: 1) The speed at which the vehicle is traveling when you start braking and 2) The weight of the vehicle in question. Now consider that many 4x4 owners add substantial weight to their vehicles in the form of technical accessories such as larger fuel tanks, fridges, roof racks, luggage storage systems, roof-top-tents, winches etc. In addition to this, many 4x4 owners tow boats, caravans or heavy off-road trailers. It is also common for engine outputs to be substantially increased on 4x4’s to allow for fairly high-speed open road traveling.

With this in mind, we would like to point out the following facts: If the weight of a vehicle is doubled, twice as much heat will be generated under braking. If speed is doubled, four times as much heat will be generated. If weight and speed are doubled, eight times the heat is produced under braking.

This explains why we have recorded front disc temperatures of up to 600 deg C on 4x4 vehicles during testing. These extremely high temperatures were recorded on heavily loaded 4x4’s, typically while descending mountain passes or towing heavy caravans, off-road trailers or boats. Brake temperatures this high would normally be associated with high-performance cars under fast-road or even track use and immediately explains the brake fade, disc distortion and high disc / pad wear that many 4x4 owners are reporting with standard brake components. The table below shows examples of the rise in front disc temperatures measured on a popular double-cab 4x4 vehicle when braking from various speeds with different loads. While reading through the table, bear in mind that typical OEM and aftermarket brake pads will begin to fade considerably from disc temperatures of 300 – 350 deg C. Also consider that the table below shows temperatures resulting from single stops. The compounding effect off multiple, consecutive brake applications, such as experienced when descending long mountain passes, can lead to far higher disc temperatures.

Vehicle weight: Vehicle speed: Rise in front disc temp:
Single stop from 120kph
Vehicle weight + 2 adults + full tank of fuel 1 stop from 120kph
(75mph)
175 deg C (347 deg F)
Vehicle weight + 2 adults + full tank of fuel + 2 kids
+ 350kg (770lb) of accessories.
1 stop from 120kph
(75mph)
225 deg C (437 deg F
Vehicle weight + 2 adults + full tank of fuel + 2 kids
+ 350kg (770lb) of accessories + 800kg (1760lb) off-road trailer.
1 stop from 120kph
(75mph)
305 deg C (581 deg F)
Single stop from 130kph
Vehicle weight + 2 adults + full tank of fuel 1 stop from 130kph (81.25mph) 208 deg C (406 deg F)
Vehicle weight + 2 adults + full tank of fuel + 2 kids
+ 350kg (770lb) of accessories.
1 stop from 130kph (81.25mph) 267 deg C (513 deg F)
Vehicle weight + 2 adults + full tank of fuel + 2 kids
+ 350kg (770lb) of accessories + 800kg (1760lb) off-road trailer.
1 stop from 130kph (81.25mph) 361 deg C (682 deg F)
Single stop from 140kph
Vehicle weight + 2 adults + full tank of fuel 1 stop from 140kph (87.5mph) 244 deg C (471 deg F)
Vehicle weight + 2 adults + full tank of fuel + 2 kids
+ 350kg (770lb) of accessories.
1 stop from 140kph (87.5mph) 313 deg C (595 deg F)
Vehicle weight + 2 adults + full tank of fuel + 2 kids
+ 350kg (770lb) of accessories + 800kg (1760lb) off-road trailer.
1 stop from 140kph (87.5mph) 422 deg C (792 deg F)

In response to requests from 4x4 owners, we applied the materials and technology used in our fast-road and race discs to the development of our All Terrain 4x4 disc design. Careful consideration was also given to the unique braking conditions encountered by serious off-road enthusiasts, including presence of mud, water, sand and the need for good brake modulation under very slow, technical descents.

Whether braking from highway speeds on tar roads or negotiating a steep descent in wet, muddy conditions, our All Terrain Series upgrade kits combine a purpose designed high-performance disc, matched to a set of carefully selected high-performance pads to offer vastly improved brake performance and durability on heavy 4x4 vehicles and SUV’s.