i have the complete g60 front brake swap with stainless lines and 22mm master cylinder. i must say it is one of the best mods i have done to improve the truck. huge difference from the slotted rotors and hawk blue pads on my 9.4s and i am just running the oe pads and rotors on the g60 brake setup.
I put 167k on a company owned 08 Silverado 4.8l. Oil, brakes and tires were all it ever needed and I beat the snot out of that truck.
Cross drilled and Slotted Rotors | EBC "Redstuff" Kevlar
I had a similar problem years ago with a set of Mintex pads. This might not be the recommended way to fix it, but I just rubbed the brake pads on the concrete floor to wear them down a little so they fit...never had a problem with them after that.
I have EBC Red Stuff pads on all of my other cars, and they have been a very good choice. excellent stopping power & fade resistance, great pedal feel, no noise, and very low dust.
X2 hps had them on my mkv and loved them. Even did a track day with them
As for the brakes the S2 16v's should take it hands down.
But the MK2 brakes by far hands down feel better and seem to grab better. I'm not sure why that is, they are actually more worn than my Mk1.
I have the DBA 4000s and really like them--but I have the Mintex pads and in the cold, they squeel horribly. But, low dust and decent performance.
If there's a sore point on the Si, it's the brakes. It's that initial application is far too touchy, making smooth heel-and-toeing difficult especially when only light brake application is required. That abruptness proves annoying even in hard use, and the slightly spongy pedal feel doesn't help matters.
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