Alcon will unveil its Next Generation Rally Caliper (Part Number: CAR2349H106) at PMW Expo 2025 in Cologne, delivering championship-proven technology for WRC27, Rally2, and Rally3 competition. The advanced four-piston design represents the culmination of over four decades of rallying expertise, offering manufacturers unprecedented versatility and performance across all competitive tiers.
Highlights
- Heritage-Driven Development: Leverages technology refined through victories with Audi Quattro Group B, Toyota Celica, Citroën WRC, Volkswagen Polo R WRC, and Toyota Yaris WRC platforms since 1983
- Regulatory Compliance: Purpose-built to maximize performance under forthcoming WRC27 regulations while maintaining compatibility with Rally2 and Rally3 specifications
- Material Versatility: Features selectable piston materials including Aluminium, Stainless Steel, Titanium, and proprietary SMART V.2 compound for application-specific optimization
- Technical Presentation: Live engineering briefing scheduled for Wednesday, November 12 at 11:00 AM with Alcon’s development team
Four Decades of Championship Pedigree
Since 1983, Alcon has maintained continuous involvement at rallying’s highest competitive levels. The company’s client roster spans iconic platforms including the Audi Quattro Group B era of the 1980s, Toyota Celica campaigns of the early 1990s, Sébastien Loeb’s record-setting Citroën programs, and Volkswagen’s 2013 championship resurgence with Sébastien Ogier.
Since 2017, Alcon has equipped Toyota’s Yaris WRC platform, contributing to the manufacturer’s sustained competitive success. Beyond top-tier applications, the company has achieved significant traction in customer-focused Rally2 categories, where properly developed machines regularly challenge Rally1 entries in stage results despite substantial cost differentials.
Engineering for 2027 Regulations
The Next Generation Rally Caliper directly addresses the forthcoming regulatory framework while maintaining backward compatibility with current Rally2 and Rally3 specifications. According to Garry Wiseman, Chief Engineer at Alcon, the development program capitalized on the company’s vertically integrated manufacturing capabilities and proprietary processes.
“The Next Generation Rally Caliper embodies everything Alcon stands for: versatility, cutting-edge technology, and performance without compromise,” Wiseman stated. “Our in-house capabilities and advanced manufacturing methodologies have delivered a product that will provide teams with the confidence to push the limits on every stage, from WRC2027 to Rally3.”
Technical Specifications and Architecture
The caliper employs a forged monobloc construction housing four pistons in a differential bore configuration. Teams can specify bore combinations of Ø34.9 mm / Ø38.1 mm or Ø38.1 mm / Ø41.3 mm to optimize brake torque distribution and pedal modulation characteristics for specific applications.
Core Technical Parameters:
- Construction: Forged monobloc four-piston design
- Bore Options: Ø34.9 mm / Ø38.1 mm or Ø38.1 mm / Ø41.3 mm differential configurations
- Piston Materials: Aluminium, Stainless Steel, Titanium, SMART V.2
- Structural Performance: Market-leading stiffness-to-weight ratio for consistent brake modulation
- Mass: 1.82 kg
- Pad Interface: 4423 profile, 16 mm thickness, 64.5 cm² friction area
- Surface Compatibility: Optimized for both gravel and tarmac disc applications
- Serviceability: Integrated protective bleed screw caps for enhanced durability
The material selection matrix allows teams to balance thermal management, unsprung mass considerations, and durability requirements across diverse competitive environments.
PMW Expo Technical Briefing
Alcon will conduct a technical presentation on Wednesday, November 12 at 11:00 AM, focusing exclusively on the 2027 regulations-compliant rally caliper architecture. Tim Allen, Business Development Manager, and David Clegg, Principal Brake Engineer, will lead the session and remain available for technical consultation following the formal presentation.
The briefing will provide detailed engineering insights into the development process, material science considerations, and application-specific optimization strategies for the next-generation platform.
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