Hi Mike,
Truth to be told, even the stock brake setup with some aggressive pads will give you enough power to stop the car. If the ABS is engaged you already reached the limits.
Now, if you race your car a lot, the stock parts won't last long and they need to be serviced more often.
The only reason you would upgrade your calipers is to improve the "wear and tear" of the brake components and for better heat dispersal.
What stops you is the tires. Better tires = better stopping power.
When was the last time you service the calipers? Are you using the TSX rotors as well?
With the TSX setup I never had a problem with the pads not wearing evenly. Maybe the piston is not traveling properly? Were the calipers brand new when you got them or were they used? If they were used, did you service them before installation?
"Chunking" usually happens when the pads are not wear-in properly. Make sure you follow the instructions when wearing-in the pads. Other than that ... don't know to be honest :|.
The DTC60 pads are very aggressive. They will bring a lot of extra heat on your rotors and is normal for the boots to crack. That means service your brakes at least once a year - preferably before winter (if you have winter in your area

).
I never looked to see if you can find better boots that resist the heat ... maybe that's something you want to look into.
Btw, with these pads, use the heat-shields that comes with them. They do help a little.
Yes, the TL-S calipers are MUCH bigger than the TSX ones. I believe I have a picture to compare them on my DIY. The only reason I've upgraded to them was the turbo that I've recently finished installing (new DIY to come soon

). The TSX setup would not resist the abuse for too long.
I run the TL-S setup with the same pads you are using and so far I see no wear on the boots. And everything works just fine. The only thing is that the calipers don't looks as nice and shinny anymore. Heat and dust faded the paint a little :|.
As for the wearing of the wheel well plastics, usually on stock suspension, a good alignment with some negative camber will take care of that.
I run Skunk Pro-c with a decent drop and got the same issues (with good alignment and some camber). I've end up removing the plastics and roll the fenders just a little bit. No more problems.
I'm glad you enjoyed my DIY!
