Reconditioned Brembo Calipers, REBUILD THREAD
 

We have been sent a full set of Brembo Calipers to recondition by a member off another forum. We have decided to take pictures and document the process best we can

This is ready for stripping

They arnt the worst set we have had but they certainly need some TLC

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Starting with the rears

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As usual some of the pad guide plate screws are corroded and need chiseling out

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Looks to be slight corrosion on the lugs, normally it is worse than this on a bad set, i would rate this mild corrosion.

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We will update again shortly


We have now Shot blasted the rear halves with the mounting lugs on, as you can see there is pitting/corrosion in various places. Nothing structural though so can all be sorted with our special metal filler.

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We have applied our metal filler which is to be left overnight before been baked in to oven to fully cure in the morning
It may not look pretty now but once sanded back to shape you will see the difference. Once sanded it may be that they require another small application of the filler to tidy up any final blemishes.

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how much to refurb a pair of rear brembo's and paint them red with new decals please

cheers

matt

£220.92 including a new seal kit and powder coating with decals. This included minor filling work. Major filling may be a little extra

http://www.scoobyworx.com/brembo-2-p...ers-5613-p.asp

Extra's

If mounting lugs need welding £35 per pair of calipers

Re-Thread/Helicoil on stripped threads £12 each if required.

cheers,whats the turn around time?

They're some rotten calipers - looking forward to seeing these come together:thumb:

Turn around on clean set needing no filler 2 days generally, more work they need to make them look nice longer it takes, if they need filler and are medium corrosion to bad then it can be 3-7 days with cure times. Also depending on workload and how many sets we currently have in to recondition

Once Shot blasted most brembo calipers look like this. Wait till we start the fronts, they are usually worse :)

ok matey,i will have a look when they get removed

The other half of each rear caliper is now blasted and filled.

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The rears have now also been baked to cure the metal filler, il get these filed down tomorrow hopefully and update again,

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Now time to start the fronts :)

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This really isn't what we want. A snapped bleed screw in the fronts. Time to start drilling

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Now we tried drilling and using an easy out and also heating up the housing to try and release the seized bleed screw to no avail, even the easy out snapped in the drilled hole. So i had one final option before arranging for it to be spark eroded (this removes snapped bolts/bleed screws without damaging threads). I went to see Adrian who is a fabrication/welder expert a few units down who is great at solving snapped bleed screw issues, with a washer welded on and then a nut welded to the washer it came out.

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Interesting , I like these detail how to threads with lots of pictures :thumb:

A little more progress

Corrosion on the front calipers is also quite bad, front halves arnt bad though

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The rear halves are quite corroded, thread repair has already been done prior to us receiving these on one of the calipers

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Filler is applied

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Why is there so much pitting round the bolt holes ?

Its a common trait of the Brembo calipers, the general opinion of most people is poor quality metal when cast when new. The Subaru 2 pot rears do the same though so it may just be the cast alloy used does this when not protected.

As long as they are structurally sound though once filled and powder coated they will be fine and protected from further corrosion also.

Its to do with the one part been ferrous metal and one been non ferrous metal this accelerates the pitting. I'm sure somebody who knows more about metals and reactions may be able to clarify exactly what happens and why :)

Thanks for such a thorough and good answer :thumb:

Aah, a nice blob of JB Weld to fill the pitting! Used it many times myself! :)

Nice write up!!!!

Its not JB Weld lol, i wish it was as JB weld is about £10 this is £40 a tin and thinner it uses is special and £20 a tin. £70 a kit with delivery.

This is a special powder coating filler

Sorry for the delay in updating this thread but we had a large engine change job on the last few days which has kept us busy

The front halves of the front calipers were the least corroded and these are now completed. The was some corrosion on the face of one which proved a pain and had to be flatted and re coated as it bubbled through the powder coat but looking good now.

The rear halves of the front calipers are currently having their second lot of the filler bakes off in the oven as they needed more work

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Thats cool. Was wondering as it would have to be electrically conductive to work in powder coating process. JB Weld is, but not much.

Nice job on the calipers!

This we use even sands/files off and leaves it shiny like the metal so an invisible repair as such :)

Looking forward to seeing how difficult it is to replace the pistons and seals, I've just replaced my front discs and pads today and the front callipers ideally need a strip down and clean, one of the piston seals looked like it was due to be changed aswell.

Nice work

Mick

Progress Today........

Final fill cured on the front rear halves

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Filed and taking shape, be powder coated tomorrow :) after i have done a re-thread as they are shot in this one

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One of the rear caliper front halves coated and ready for building up

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Looking good :thumb:

I see you sell a new seal kit, Is this easy to change as mine is leaking on one side?

Yes they pop out by using a broddle there is a small recess to pry them out with.

Can you supply just the outer dust seals Darrell, rather than a complete seal kit?

Good job on the refurb :thumb:

Brembo seal kits are only available in full kits, we cant split kits unfortunately as everybody wants the same parts.

will be ordering a set later next week:thumb:

and a broddle?? what is that?

Ive come in on Sunday to finish these off as i am now getting a backlog of calipers at the minute.

First job was to drill the damaged thread out ready for the re thread

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Then tap the thread out

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Fit the re thread stainless thread

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They need trimming off with a sharp pair of cutters

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So your left with w nice neat thread

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Genuine Seal Kits

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Use Silicone grease on the new seal, smear it round with your finger

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You have to grease the inside of the new seal also as they are tight to push in otherwise

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Finally they just need building up tomorrow once we have painted the pad guides and bolts back up :)

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Broddle is a small tool which you can buy http://www.ebay.co.uk/itm/Carpenters...-/290488091472

I use Snap-On ones but this is first i found as an example

Cleaning up the reads for the guide plate bolts as oem are thread locked in.

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All built up and finished :)

These turned out to need a hell of a lot or work with filling along with a re thread as well. But they have made a nice set of calipers now finished

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Very nice indeed :thumb: