Anyone know how to rebuild Brembo Calipers?

[Westy]

Hi guys,

I have managed to get a set of Porsche Boxster front calipers for an absolute bargain £180 but they could do with new seals and powder coating.

I've done a little search on the net for guides but I just seem to find links to seal kits as opposed to helpful guides on how to remove pistons, replace seals, and clean up the caliper.

I have read that it's best to get the caliper powder coated before doing the rebuild so I'll get this done first.

Has anyone got any experience with rebuilding calipers, any tips, or guides?

I did find this one guide from the lotus owners club but I was more interested in a Porsche specific one if possible:

How to Rebuild a Brembo Caliper - SELOC TechWiki

 

[mk1chopper]

Isnt there a guy on the mkiv forum who refurbs brembos might be worth getting in contact with him, I refurbed the audi 80 brakes i fitted to my mk1 golf, used a bike pump to push the pistons out removed the seals and had the calipers sand blasted, then I cleaned and painted, then refitted seals and pot. Not sure if theres any special method for brembos or 4 pots but my refurbed brakes never failed me.

 

[Syvo]

i know its not the porsche calipers this may help as they are brembo calipers.

DIY: Brembo Caliper Disassembly - NASIOC

 

[Syvo]

or this one westy

Brake Caliper Rebuild - Do-It-Yourself Instructions For Racers - Circle Track Magazine

 

[Westy]

Isnt there a guy on the mkiv forum who refurbs brembos might be worth getting in contact with him, I refurbed the audi 80 brakes i fitted to my mk1 golf, used a bike pump to push the pistons out removed the seals and had the calipers sand blasted, then I cleaned and painted, then refitted seals and pot. Not sure if theres any special method for brembos or 4 pots but my refurbed brakes never failed me.

Yeah Dave, I've been told he doesn't do it any more as he is too busy with his actual day job lol. I might contact him and see if he'll be able to help.

 

[Westy]

I've contacted DaveB so I'll see what he says. He used to do a full rebuild and supplie the bolts and carriers for about £200. I've calculated that onece they are on my car and working the whole kit would have only cost around £500

 

[Prawn]

I'm fairly sure Dave is out of the brake business completely at the moment, he's a commercial Airline Pilot by day, so spends a lot of time out of the country.

 

[Westy]

I'm fairly sure Dave is out of the brake business completely at the moment, he's a commercial Airline Pilot by day, so spends a lot of time out of the country.

That's a big shame. I've got now problem with rebuilding the calipers myself with the guides above and it will save me some cash but I was hoping to source some carriers from him.

 

[mk1chopper]

That's a big shame. I've got now problem with rebuilding the calipers myself with the guides above and it will save me some cash but I was hoping to source some carriers from him.

Cant bill sort you out with carriers?

 

[Westy]

Cant bill sort you out with carriers?

This is a possibility, I'll PM him.

 

[Westy]

Just messaged these guys on eBay:

eBay My World - creationsmotorsport_com

They do loads of other caliper adapters for around £90. They said they do them for the boxter calipers but are currently out of stock and should have some more in 2 weeks time. Which gives me enough time to get them refurbed

 

[Sam_]

I see they do the Cayenne adapters. They would be some hefty *** brakes

 

[Westy]

I see they do the Cayenne adapters. They would be some hefty *** brakes

6 pots but the master cylinder on our cars wont be able to shift all those pistons!

 

[Syvo]

6 pots on a s3

 

[Westy]

Had a crack at this tonight but struggled to get the pistons out as I dont have the correct tool as seen in this guide:

Brake Caliper Rebuild - Do-It-Yourself Instructions For Racers - Circle Track Magazine

I tried using a bike pump as heard some people had success with one but it wont work. Any other ideas?

 

[Westy]

Looks like I need to use a compressed air gun but now need to find somewhere that will let me use one.

 

[Westy]

I've found Brembo piston removal wrenches but they cost a bomb!

£402 for the full set of wrenches

 

[Syvo]

ive got air gun but live miles away from ya m8 sorry.

 

[Westy]

ive got air gun but live miles away from ya m8 sorry.

Thanks for dangling the carrott mate

I'm going to try and prize them out with 2 flat head screw drivers later, like this:

 

[Westy]

It can be done with a foot pump but I've only managed to get 2 pistons out of one caliper a 1 piston out of the other because the seals were split

 

[mk1chopper]

Could you hook them upto a car tyre and use the pressure from the tyre to pop the pistons?

Can you also remove the pipe connect both sides up and pop out one side at a time?

 

[Westy]

Could you hook them upto a car tyre and use the pressure from the tyre to pop the pistons?

Yeah I see no reason why not. I now need to gently prize out the other pistons.

 

[Westy]

I'm still struggling to get the other pistons out and there doesn't seem to be any piston removal tools about on the net except the stupidly priced Brembo ones. I'm a bit reluctant to use 2 screw drivers as I dont want to damage the pistons.

Anyone got any other bright ideas?

 

[mk1chopper]

Your replacing the seals arnt you? if so see if cutting the seals out helps, get the caliper in a vice and try using molegrips to prise the pot out, you could use paper towel to stop the grips from marking the pots..

 

[Westy]

Your replacing the seals arnt you? if so see if cutting the seals out helps, get the caliper in a vice and try using molegrips to prise the pot out, you could use paper towel to stop the grips from marking the pots..

Already cut the seals but the pistons are extremely stiff to pull out. I really can see any alternative but to prize them out with screw drivers or grips like you say but this will increase the risk of damage. I'll give it a go later in the week.

 

[mk1chopper]

Id go with grips first as you should be able to twist and pull

 

[Westy]

Id go with grips first as you should be able to twist and pull

I'll give that a whirl mate, cheers for the idea.

 

[ScottD3]

Grips on the pistons??
I would not want to put any thing on the piston that could cause damage or marks.
That would wear away the seals and cause them to leak.

Are you unable to do the screw driver as in the link above?

I've not read all of this thread so i might have missed something.

 

[Westy]

Grips on the pistons??
I would not want to put any thing on the piston that could cause damage or marks.
That would wear away the seals and cause them to leak.

Are you unable to do the screw driver as in the link above?

I've not read all of this thread so i might have missed something.

I did use the 2 screw drivers like the link above but it is still quite risky and isn't as easy as the above picture makes it out to be. I'll try again and see how I get on.

 

[mk1chopper]

Grips on the pistons??
I would not want to put any thing on the piston that could cause damage or marks.
That would wear away the seals and cause them to leak.

Are you unable to do the screw driver as in the link above?

I've not read all of this thread so i might have missed something.

Thats why i said use some paper towel, if you have an old bike inner tube you could use this too, cut some stips and wrap around the grip or pot itself

 

[ScottD3]

I did use the 2 screw drivers like the link above but it is still quite risky and isn't as easy as the above picture makes it out to be. I'll try again and see how I get on.

Needs a vice or a desk clamp by the looks it.
A helpfull friend as well might work.

You could put tape round the end of the screwdrivers to help protect the surfice.

 

[Westy]

Needs a vice or a desk clamp by the looks it.
A helpfull friend as well might work.

You could put tape round the end of the screwdrivers to help protect the surfice.

I'll try the tape on the screw drivers. I tried a helpful friend and he turned out not to be very helpful and got me in this situation in the first place lol.

 

[voorhees]

YouTube - ‪Rebuilding brake calipers‬‏ I don't know if this is of any use

 

[ScottD3]

Done it yet?
Any pics or update?

 

[Westy]

Yeah update for you:

These calipers are a pain to refurb. I am struggling to remove the dust boots around the pistons as they are squeezed between the piston shaft.

I called a brake company called Biggred hoping that they would refurb them for me but even they won't touch 4 pot brembos as they are a pain!

I am trying to find a refurb company that will do brembos.

 

[ScottD3]

Can you seperate the two halfs of the calipers?
If you can seperate the two halfs of the calipers and get a slid hammer over piton end (where the screw drivers go), I think that might do it.

 

[Westy]

Can you seperate the two halfs of the calipers?
If you can seperate the two halfs of the calipers and get a slid hammer over piton end (where the screw drivers go), I think that might do it.

They're 1 piece calipers which is the beauty of them. It means they are lighter and more ridgid than the 2 piece ones. Getting the pistons out is Childs play compared to getting the dust boots out!

 

[ScottD3]

Surly if the piston is out the dust boot will just pull out?
There can't be any thing else holding it in, can there?

 

[5ean]

There's sometimes a slip ring around the bottom of the boot.. I'm refurbing mr2 calipers at the moment (side project..) and i got a reseal kit for them so i just pulled the old rubbers out. Thought i got everything out until i looked at the replacement seals and seen the slip rings, they just pushed with a screwdriver once they were located.

 

[s3dave]

Dust Boots are just on a lip.... be brave