Sorry, I forgot to post the update on the larger rear calipers.
I built 38mm rear calipers because the piston area ratio front to back mimics the successful StopTech stage 1 kit. Instead of 36/40mm pistons in the front and stock 36 in the rear, this keeps the 38/42 fronts and increases the rear to 38mm. Therefore it is totally undetectable, you can use all the stock mounting points, and use factory size brake pads. I run without the brake proportioning valve cup seal, and it is better on the street, was better at a Lime Rock and Pocono track event, and an improvement in AX. Except for whatever the difference in heat rejection rates might be, it fundamentally has to be the same performance as the StopTech system.
No surprise, if some is good, more is better. For AX especially, I want more rear brake bias, probably more than some might like. So I went back to the machine shop and we agreed that we could go out to 40mm rear pistons.
Once again, a very nice improvement. After another Lime Rock event, I can go about 1.5 numbers deeper at the end of the straight without losing control or locking a front wheel. And for AX, it's better yet.
In my experience, without the cup seal, a 40 mm rear caliper still allows the front to lock first; this after two months on the road including rain, one track event, and a few AX events. I have not played with different pad compounds between front and rear, I use the same all around, so that may be a final fine tuning method.
The cost? For a do-it-yourselfer about $534 a pair, plus a set to start with. I've found them on eBay for $130-$150 a pair. Of course, you can always get Renault Alliance/Dodge Monaco rear calipers from the junkyard - it's that same thing. The machine shop still charges me $500 a pair because it's a one-at-a-time (although they have jigs to make them quicker if they get a run of 10), $22 for two Brembo piston seals, and $12 for two Renault Alliance caliper rebuild kits. Of course, your labor is priceless. After about 4 sets, I can get the calipers apart in 6 minutes, back together in about 40 minutes. The 40mm size may take longer, the stock dust boot is still used and you have to be very careful not to pinch it. I have instructions I'll share, since the service manual claims the calipers are not serviceable. Email me.
While the onlooker can't tell, the driver will notice a very, very slight increase in pedal travel. You are increasing the volume of the rear calipers, so it takes a little more to fill them. And bleeding them the first time is a little problematic; there is a long horizontal bore in the piston to house the parking brake self adjusting mechanism and I suspect that air might get trapped in there. I need to remember to pour brake fluid in while assembling.
I have two 38mm pairs left over from my little R&D effort. If anyone's interested, wants more details, questions about how good it really is, let me know.