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James's DJG Turbo Project


TheTurtleshead

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I decided to get 2014 off to a productive start, so I sneaked into the workshop and began refurbishing my AP Brakes.

 

All the pistons came straight out of one calliper easily with a bit of air… 5/6 Slid easily out of the other…. One was a bit sticky… and 10 bar of air pressure wasn't enough to shift it!

 

I ended up using a combination of spare brake line, spare clutch master cylinder and a puller. I set it up on the bench, disconnected the other three pistons by removing the cross pipe on the calliper, bled it all up and… 'Boom' It came out like a bullet. :D Turns out one of the scraper seals was a bit tired and had disintegrated and jammed the Piston… A good lesson on why to refurbish second hand brakes before fitting.

 

Turns out Co-Ordsport sent me the wrong seal kit… The seals are correct… but I only have one per piston per calliper, and my callipers run two seals per piston. One dirt scraper seal and another fluid/pressure seal. I have a CP4518 Seal kit, and I need a CP4519-CEJ Kit.

 

Everything is in good condition internally though.. so I'm happy. :)

 

Anyway here are some crap pictures….!

 

This really is a dirty, nasty messy job lol!

 

Began Stripping the first one down:

attachment.php?attachmentid=178860&stc=1&d=1388622245

 

Cleaned up the stainless steel pad springs and bolts:

attachment.php?attachmentid=178861&stc=1&d=1388622245

 

Here's the Airline setup:

attachment.php?attachmentid=178862&stc=1&d=1388622245

 

Combination of "wedgey things" to position the pistons aaaaaalmost out:

attachment.php?attachmentid=178863&stc=1&d=1388622245

 

They all came straight out on this one:

attachment.php?attachmentid=178866&stc=1&d=1388622336

 

The bench mounted pressure setup:

attachment.php?attachmentid=178864&stc=1&d=1388622245

 

 

All stripped and ready for cleaning and paint:

attachment.php?attachmentid=178867&stc=1&d=1388622428

attachment.php?attachmentid=178868&stc=1&d=1388622428

 

Cleaned up the Brackets… Pretty pitted but rust free and still structurally sound. :)

attachment.php?attachmentid=178869&stc=1&d=1388622428

 

 

 

Will update with more progress when I finish them. :)

Startcaliper.jpg

Clean Shims.jpg

Air setup.jpg

Wedgeing air.jpg

Rig one.jpg

rig two.jpg

Finally all out.jpg

ready 1.jpg

ready 2.jpg

Clean brackets.jpg

Edited by TheTurtleshead (see edit history)
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Fitted my Stubby Aerial that I bought from Mas today… Same as the ones from Steve's group buy, brand new in the wrapping. :) Looks a lot smarter.

 

Some pics of the steps;

 

Old Bezel:

attachment.php?attachmentid=178998&stc=1&d=1388936549

 

Removed Interior trims:

attachment.php?attachmentid=179004&stc=1&d=1388936617

 

Fitted new support- It needed shortening and the hole making into a slot with a dremel for it to sit in the right place:

attachment.php?attachmentid=179001&stc=1&d=1388936549

 

New sleeve installed and tightened down:

attachment.php?attachmentid=179002&stc=1&d=1388936549

 

All Done. :)

attachment.php?attachmentid=179000&stc=1&d=1388936549

attachment.php?attachmentid=178999&stc=1&d=1388936549

 

Also treated it to a clean and a fresh coat of Poorboys on the wheels:

attachment.php?attachmentid=179006&stc=1&d=1388936617

 

I also glued on the Exhaust surround that I've had sitting around for over a year. :D I wasn't sure about it, but tried it on the car the other day when Littler was here, and I think it adds some aggressiveness to the back, so decided to whack it on.. will get a better pic when the silicone dries.

 

attachment.php?attachmentid=179005&stc=1&d=1388936617

Aerial1.JPG

Fitted Rear 3:4.jpg

Fitted.jpg

Inside3.jpg

Bezel Fitted4.jpg

Aerial2.jpg

Exhaust Surround.jpg

Finished 3:4.jpg

Edited by TheTurtleshead (see edit history)
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