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Caliper refurbishment

bennyboy

New member
Chaps, anybody had this done recently? I know that RPM offer a refurb and painting service for £270/pair inc. VAT, which seems quite reasonably to me. And another local firm will match that. But is it worth the extra cost to get the pistons replaced, which Promax would do for me?
 
I've done 3 pairs now, 2 to go on my car and one pair which I've just sold.

The tricky bit is getting the bolts out which hold the pad retaining plates in place. These have a crapy little hex head and are ususally unrecognisable with rust. Thy're put in with thread lock as well. The only way I found is to weld a nut over the head of them. The heat eases the corrosion and the nut then gives you something to get a spanner onto. You need to rig up heat shields to protect the seals while you weld.

Once these are out I had the shot blasted and then gave them a fresh coat of paint and new bleed nipples before re-fitting the plates with stainless bolts.

Be careful getting the bleed nipples out, I sheared one of mine and it was a sod to get out!
 
I've done this myself just recently, I had to do the same as "awattam" above and have a nut welded onto the bolts to get them out, the hex head had corroded into a nice cylindrical hole on most. I didn't have time to do a proper job painting them so just quickly scrubbed back what I could (mostly the lacquer peeling away) then painted over with heat resistant paint, doesn't look great but it did the job.
I also put heat resistant sealant between the plates and calipers when putting them back in, with new stainless steel bolts and stainless bleed nipples. I used a flare spanner and didn't have any problems with any of the connections, although I also spent my spare time dousing them in WD40 for a while before hand.

If you haven't got the calipers off be careful of the solid pipes on the rears, I sheared one of mine off as the fitting had corroded to the line. Not a big deal but hard to route a new line the same way around the trailing arm.

The pistons are DAMN expensive, I was talking to Andy at Promax about this and he said the reason they don't offer a refurb service is it simply doesn't add up, the costs of replacing all the bits plus the time to take it all apart and paint barely make it worthwhile.
In my case I didn't need to replace any of the pistons, even though one of my dust caps had gone gammy and the plate lift and corrosion on mine was horrendous on all 4. I just had to replace a few dust caps, one I broke the other had rusted on one side but hadn't done any other damage.

Sorry for the long post - basically don't bother replacing the pistons unless you NEED to!

Why is it you're refurbing, is it plate lift or do they look tatty?
 
I don't know the calipers on a 944 but in general it's the pistons that need changing because they get pitted. You can't risk a bodge job - I'd phone Classicar Automotive (01625 860910) - they advertise in the Club magazine.
 
I've only ever refurbiished calipers with good dust seals and piston. I have a couple of scrap calipers which had damaged dust seals but good pistons. I may have some of these pistons available if you want them.
 
The last time i did a set of calipers the cost of 1 piston incl seal kit was around £17 + VAT...If you need all 8 [4 per caliper],,then it gets £££££££££££
But that was about 2 years ago, so the price might have gone up...
 
I got the dust caps from Promax, I think the cost of a set of scrapper ring piston kits has gone up to ~£30 per piston! Don't know about the dust cap type though.

I rang Classic Automotive and got a price of something like £200 per caliper for a refurb, I'm not sure exactly, it was high enough for me to not bother writing it down! Saying that though, from what I've seen posted about them it'll be a proper job!

I must say every single piston on mine was in perfect condition down the sides, with only a few marks on the tops, maybe I was lucky though?
 
Oh well, at £200 a corner looks like I might end up buying new M030 calipers instead for the 968.

Lucky that on my S2 it has always been caned so the calipers are in as good a condition as when I bought the car 9 years ago. Seriously I am convinced it is lack of use and to gentle use that leads to bad caliper corrosion. Mind you in 73K miles I did go through 5 sets of front disks and pads (5th still have plenty life in them though). I hope those seals are OK though.
 

ORIGINAL: Big Dave

the cost of 1 piston incl seal kit was around £17 + VAT...If you need all 8 [4 per caliper],,then it gets £££££££££££

That's why a lot of us went out and bought a new set of the huge Big Blacks from a 928GTS (or reds from a 993TT). When the exchange rate was better they were only £200 each from the States
 

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