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Behold81

Original Poster:

2,443 posts

53 months

[news] 
Sunday 7th October 2012 quote quote all
So a stupidly delayed process as I'm just plain lazy!!!!!but here are my new brakes all overhauled.

This will be a bit pic heavy..... So the brakes had to come off to do this properly. Little tip I found out is wedge the brake pedal on to stop the brake fluid running free when you unbolt them. I unbolted and bagged the end to cover drips and it seemed to work well.

Once removed the looked VERY sorry from all the years of brake dust and ally oxidising.





Bit of scrubbing and cleaning up and they looked clean enough to start painting. Before this I tried releasing of all the bolts. Aft 4 bleed nipples didn't come out and NONE of the bolts to split the calipers would move I decided not to split them. Had to use a company to drill out the old nipples and he did a great job doing it with out wreaking the thread. Before I started painting I removed each piston in turn using a hand pump! blocked of three pistons with wood and pumped up the pressure to pop each out. At this point I realised many of my pistons were stuck solid. One caliper each piston moved at different pressures. Once each was out I removed any corrosion build up. Actually only 2 pistons on all 4 calipers had been stuck due to corrosion. The rest was the seals were shot. One piston would not go back in due to the seal being that bad.



After a bit of looking online I used hammerite as the weapon of choice. Few coats to make it look respectable left them ready to have the faces polished up to completed the process. To look like is.



Once painted I removed all 4 pistons to replace the seals. To do this out cam the pump again. Airline would make this easier! Using a bit of wood and paper I pushed all 4 out as far as I could keeping the seal then priced each out with screwdrivers and even pressure on each side till all were out. Rplaced the seals and popped it all back together.







finally refit to the car and add some two piece disks... Looks good. Bleeding them fully today as I have lost my eazybleed.




Britsud

288 posts

30 months

[news] 
Sunday 7th October 2012 quote quote all
Great job always a fan of have a go

They look great

ARAF

16,621 posts

107 months

[news] 
Sunday 7th October 2012 quote quote all
Very nice. Did you clear lacquer them after polishing the faces, or leave them bare? scratchchin

Gary H 2008

3,130 posts

73 months

[news] 
Sunday 7th October 2012 quote quote all
Great job. What make are the discs?

Behold81

Original Poster:

2,443 posts

53 months

[news] 
Sunday 7th October 2012 quote quote all
ARAF said:
Very nice. Did you clear lacquer them after polishing the faces, or leave them bare? scratchchin
I tried to lacquer them but found out hamerite and lacquer don't mix.... So there bare now. Will just brasso them every month or so.

At the moment that's the least of my worries. Can't get them to bleed out the air. Bled all four corners about half a resevior each corner and its still hitting the floor. If pumped and held it holds and if driven a bit and pumped will lock the brakes.

Some reason there is an airlock I can't get out.
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Behold81

Original Poster:

2,443 posts

53 months

[news] 
Sunday 7th October 2012 quote quote all
Gary H 2008 said:
Great job. What make are the discs?
There DBA disks. Bit of a bargain too. Was mentioned on here a month or so ago. Th the old design so the seller was knocking stupid money of them. I paid £252 delivered!!!! true bargain.

granada203028

1,045 posts

81 months

[news] 
Sunday 7th October 2012 quote quote all
Looks to be a great piece of work, the pictures really fill my screen!

Being creative about repair and sourcing parts should be what this forum is about, as much as empting one’s bank account into the coffers of the aftermarket tuning industry under the premise if it didn't cost a lot of money it isn't any good.

ARAF

16,621 posts

107 months

[news] 
Sunday 7th October 2012 quote quote all
Behold81 said:
ARAF said:
Very nice. Did you clear lacquer them after polishing the faces, or leave them bare? scratchchin
I tried to lacquer them but found out hamerite and lacquer don't mix.... So there bare now. Will just brasso them every month or so.
Sorry, you did say Hammerite in your original post. You would have to use an enamel clearcoat, as you can't put cellulose over enamel.

BUCKLE vxgts

79 posts

25 months

[news] 
Sunday 7th October 2012 quote quote all
Nice job you have done therethumbup Ive got to do mine soon.

Woody vt

1,890 posts

100 months

[news] 
Sunday 7th October 2012 quote quote all
I warned you! Worth it in the end though.
Almost as good as mine were

Good job.

Behold81

Original Poster:

2,443 posts

53 months

[news] 
Monday 8th October 2012 quote quote all
Ha thanks woody. You were a big help.

well_fans

4,126 posts

108 months

[news] 
Monday 8th October 2012 quote quote all
Behold81 said:
ARAF said:
Very nice. Did you clear lacquer them after polishing the faces, or leave them bare? scratchchin


I tried to lacquer them but found out hamerite and lacquer don't mix.... So there bare now. Will just brasso them every month or so.

At the moment that's the least of my worries. Can't get them to bleed out the air. Bled all four corners about half a resevior each corner and its still hitting the floor. If pumped and held it holds and if driven a bit and pumped will lock the brakes.

Some reason there is an airlock I can't get out.


check the master cylinder for the airlock, read something a while back that air can get caught at the "front" of the cylinder and only way to get it out is to disconnect each line in turn at that end and pump some fluid through it.

Behold81

Original Poster:

2,443 posts

53 months

[news] 
Monday 8th October 2012 quote quote all
well_fans said:
check the master cylinder for the airlock, read something a while back that air can get caught at the "front" of the cylinder and only way to get it out is to disconnect each line in turn at that end and pump some fluid through it.
So remove the hard lines from the cylinder? how does disconnecting them make any difference? surely the airlock is there because it cant escape due to an angle? or is it something more sinister?

I think its in my caliper to be fair as i only bled from one side of the caliper and without the caliper upright so i think my fronts might have a good few teaspoons of air in it. they were bone dry on fitting but the Master Cylinder should have still had fluid in it as it was not run dry.

Gonna get wet tonight and see.


jameshsv

4,527 posts

44 months

[news] 
Monday 8th October 2012 quote quote all
Hi their what pads are you using great job youve done

Behold81

Original Poster:

2,443 posts

53 months

[news] 
Monday 8th October 2012 quote quote all
There pagid pads at the moment. Not sure what there like not got the car running yet.

stevemac

147 posts

128 months

[news] 
Tuesday 9th October 2012 quote quote all
Enjoyed your post as I did more or less the same thing last year but (luckily) without the air lock problems..I too had sooooo much fun getting the bolts undone..especially the small ones that hold the steel runners each end of the pads Unbelievable anount of corrosion gunk under there pushing up the steel bits causing pads to bind. Should have done the photo record as you did, but never mind.... BTY Are there any more of those disks available?

snowwolf

10,173 posts

59 months

[news] 
Tuesday 9th October 2012 quote quote all
That's a great job done, I will be doing my Calipers too in the spring, Hammerite is also very good as it can withstand heat too and a nice finish.

Woody vt

1,890 posts

100 months

[news] 
Tuesday 9th October 2012 quote quote all
I fitted PF pads to mine and they were superb.

Behold81

Original Poster:

2,443 posts

53 months

[news] 
Tuesday 9th October 2012 quote quote all
stevemac said:
Enjoyed your post as I did more or less the same thing last year but (luckily) without the air lock problems..I too had sooooo much fun getting the bolts undone..especially the small ones that hold the steel runners each end of the pads Unbelievable anount of corrosion gunk under there pushing up the steel bits causing pads to bind. Should have done the photo record as you did, but never mind.... BTY Are there any more of those disks available?
I could not get mine to split so I decided that taking the guides out was a bad idea as one snap and drilling out the rest would be impossible.

I prised them forward then used a blade behind to clean up as much as poss and then worked them back flat. All but one could I get cleanly flush. So I shaved the side of the pad a bit. Done.

Can't get over how much better they feel.
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