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964/993 Brake pad min. thickness and caliper piston travel

Brakes

Vehicle Information: Year: all; Body Type: Coupe; Total Mileage: n/a;

Thank you for your consistently valuable advice and recommendations! I am continually impressed by the willingness of PCA members to share their experience and knowledge! As a PCA DE Tech Inspector, we come across some interesting questions and we rely on your expertise in advising our members.The Background: We need to be able to advise drivers as to when they should replace pads, and when they must replace them. For example, in normal configurations Pagid recommends changing pads when the pad material is reduced to 5mm (.2"), or roughly the thickness of the backing plate.Many C2 owners have upgraded to "Big Reds". More specifically, in what appears to be the most common C2 Big Red implementation, the fronts are legitimate Big Reds (993 TT calipers and rotors), but the backs are "Little Reds" composed of 965 calipers and Euro RS rotors. This configuration is common due to restricted rotor/hub selection >from Brembo; it works very well, but isn't optimal. The issue is that the 965 caliper is designed for use with a 28mm thick rotor; however, the Euro RS rotor is only 24mm thick. Accordingly, the caliper must be centered for proper operation, but even so, all pistons are extended 2mm - even with new pads installed. The Question: What is the designed maximum safe piston travel in the 965 caliper? For example, in the worst case scenario where an owner has rotors that are worn but still within tolerance and runs their pads down to the backing plate, is there sufficient overlap designed into caliper to allow the piston to extend that far without damaging seals, leakage, or worse?Thank you!

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