Well finally, the parts from Rimmers arrived!
We left Part 1 with the calipers off, and the pistons removed from one of the calipers. Because of the corrosion on the pistons I did remove, I chose to order a full set of pistons, instead of reusing some of them as planned.
In the meantime I tried some paint stripper to remove the paint from the calipers. It was a bad idea. Who ever would have thought caliper paint was pretty resistant to chemicals?
Before the next step, I had to completely strip the calipers of their seals and pistons. I popped the calipers out with compressed air, and used a small pick to gently remove the piston seal. The dust seal at the top of the bore was a bit harder because its held in with a metal retainer, which had rusted in place. To remove this I used a small pick to tear a gap in the seal, and then a narrow flat blade screwdriver to pop the retainer and seal out.
The calipers responded very well to the rust treatment, with no more corrosion hiding around the bolts on the back, and the seal retainer areas are spotless now.
For some reason Mrs Petrol didn’t think it was a good idea to bake the calipers in the oven, so I made do with cooking them with a heat gun to set the paint. The true baking will happen on the car anyway.
Yesterday the parts I ordered from Rimmers arrived, so I set about rebuilding the calipers and preparing them to go on the car.
A quick wipe out of the grease in the bores, and in went the piston seals. They slip easily into place. Just make sure they don’t get twisted during fitting and use lots of red grease.
Now, you can’t just push this retainer into place by hand, it needs to be pressed into place. I have seen many ways to do this, but the simplest was posted in a YouTube video by an Alan Phillips. Big thanks to him for posting the details on it.
Because of the bolt I used, I had a lot of unthreaded shank to cover before I could use a nut to clamp all the washers together, hence the massive lump of washers.
Push the piston down by hand until it sits just above the seal retainer. Slip the tool into the caliper, being careful to not scrape the bore opposite the piston and unwind the lower nut to push the washer against the piston.
Using a spanner, gently wind the nut down, this pushes against the top of the caliper, and will push both the piston and the seal retainer down into the bore. This pushes them in completely straight, and wont bend the retainer like it can using other methods.
I ordered a pair of new brake pipes. Only part number CRC3238 is available. This is the LH pipe for the single pipe caliper. The RH side is no longer available. I originally ordered two as I was going to cut one up to use the fittings with a new pipe that would be made up for the RH side. More on that later….
So with all the pistons and seals fitted, the only thing to do next was to fit them to the car.