So I get the car 100% finished (for this year), new headlights in, upper/lower front CA's in, new rubber, new C5 brakes... everything installed and a fresh alignment.

Two problems...

First is that after bedding the brakes I did some emergency stops, on the second one I hear a THUNK from the front right. It sounds suspiciously like the thunk that happened last year that indicated that my alignment had gone out and resulted in scrapping $400 in new rubber. Car still drives basically the same, and isn't pulling... but it wasn't pulling much last year either.

Can anyone think of something that would cause a thunk on hard braking BESIDES alignment?

Second, even with C5 brakes and fresh Hawk pads the damn car won't lock up the tires no matter how hard I hit the brakes. Pedal feels fairly firm, and doesn't soften as I hold it. Do I still have air in the system somewhere?

Headlights work great but WHAT A PITA TO INSTALL... holy crap I think I have more time into those friggin things than all the suspension work!

 

Check to make sure all the caliper bolts are tight. This happened to me and I discovered a bolt came lose.