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UncleP
Monza


Joined: 27 Feb 2019
Posts: 168



PostPosted: Mon Feb 03, 2020 11:23 pm    Post subject: Brake caliper refurb Reply with quote

I've pulled (actually had to cut the fronts) my brake calipers off as they were in need of some attention due to sheared bleed nipples. I figured since they're off I'd rebuild them with new seals and pistons but I'm having trouble finding parts.

My car is a 2000 C4 but the only rebuild kits I can find are for 996.2. were the brakes different? I can find 986 kits as well. Anyone know if the boxster shared the same brakes?
 
  
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kurlykris
Magny-Cours


Joined: 30 Jun 2014
Posts: 2656
Location: Warwickshire


PostPosted: Tue Feb 04, 2020 12:13 am    Post subject: Reply with quote

Personally I would just send them off to ProCalipers for a refurb, but it may be worth contacting them for a price on a refurb kit Thumb

I had a job at AP Racing recently and asked them of they would refurb my 996.1 calipers, you can imagine the response Grin
_________________
1998 996.1 C2 3.4 with "Aerokit Cup"
2006 987.1 Boxster S 3.2 sport chrono
2010 Mercedes E350 AMG Sport

 
  
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Marky911
Sepang


Joined: 04 Jun 2009
Posts: 2829



PostPosted: Tue Feb 04, 2020 1:22 am    Post subject: Reply with quote

As Kris says I’d ring that place or Bigg Red.

Only thing I’d say differently to Kris is do them yourself rather than give them to those places.
You’ve done the hard bit in getting them off and stripping them.
You can do a great job for under £200 for all 4. Add another £100 for nice new HEL flexi’s though.

I’d get yourself a kit (dust seals and pistol seals), Brembo nipples (as aftermarket ones are crap IME), have a local powder coating place do the calipers whatever colour you like, then get some new “Porsche” decals from somewhere like Highgate house.

It’s a great little DIY project and I cringe when I see people paying £600/£700 to have a set done by these companies.

Your piston sizes should be -
front calipers at 36mm and 40mm.
rear calipers at 28mm and 30mm.

This is listed as the same for 996.1 and 986 Boxster S.

Are you sure you need pistons? They usually clean up unless really knackered.

Good luck anyway. It’s one of those projects that makes a huge difference once done. Thumb
 
  
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Griffter
Nürburgring


Joined: 22 May 2016
Posts: 386



PostPosted: Tue Feb 04, 2020 6:55 am    Post subject: Reply with quote

Another recommendation - Brakes International

https://www.brakeparts.co.uk/shop/Porsche/911/97-04/911%20996%203.4%20&%203.6%20Carrera%20&%204/

They don’t seem to stock a kit either, but they do suggest you contact them for help. Their listing suggests 996.1&2, C2&4 are the same.
 
  
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UncleP
Monza


Joined: 27 Feb 2019
Posts: 168



PostPosted: Tue Feb 04, 2020 8:48 am    Post subject: Reply with quote

Cheers lads. Some good info in here regarding compatibility and piston sizes. I can find 996.2 kits including all seals and pistons for about £50 a corner.

I could probably just clean up, paint and stick back on the car but it'd be daft not to do them while off.

No intention of sending them off. I've done the job before and it's not that difficult. Besides, mine would end up costing a fortune with the sheared bleed nipples and seized main line.
 
  
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911Time
Spa-Francorchamps


Joined: 25 Sep 2018
Posts: 273
Location: Staffordshire


PostPosted: Tue Feb 04, 2020 11:59 am    Post subject: Reply with quote

Pistons are plated in Hard Chrome, so unless they're scored or pitted, they shouldn't need replacing.

Although a lot of refurbishers use Powder Coating, VHT Caliper Paint is superior as PC tends to discolour under hard use, because it's cured at a low temperature (180-200 Deg C).

There's a good reason why manufacturers such as AP and Alcon use spray finishes, (such as commercially available Xylan) but for DIY, a good quality VHT Caliper Paint/Clear will be perfect Thumb
_________________
Mark


I'm not a perfectionist - I just want everything done 'Right' Wink

Current: GT Silver 991.1 C4S with a few 'special bits'. Previous Owned: C63 Estate, BMW e92 330d Coupe (700Nm/Custom Exh/Map/BBK/Quaife/Breytons), ML63AMG, Alpina e46 B3S Coupe, Alpina e36 B3 Coupe, Lotus Excel SE, Alfasud Green Cloverleaf Ti, Lancia HPE, Capri 2.0S, Marina 1.8 (don't laugh it was my first road car). Bikes: Suzuki TL1000R and BMW R1100S AC Schnitzer.
 
  
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UncleP
Monza


Joined: 27 Feb 2019
Posts: 168



PostPosted: Tue Feb 04, 2020 12:45 pm    Post subject: Reply with quote

Thanks to the info here I've been able to source kits and all the parts individually so I'll probably just buy the seals and only replace the pistons if they're gubbed.

I'm taking some parts up to the powder coater on Thursday but I think I'll stick with painting the callipers. Got the apparatus for doing small 2k spray jobs at home.

Thanks all.
 
  
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TonyC911
Nürburgring


Joined: 06 Jun 2016
Posts: 441
Location: High Wycombe


PostPosted: Tue Feb 04, 2020 10:16 pm    Post subject: Reply with quote

UncleP wrote:
Thanks to the info here I've been able to source kits and all the parts individually so I'll probably just buy the seals and only replace the pistons if they're gubbed.

I'm taking some parts up to the powder coater on Thursday but I think I'll stick with painting the callipers. Got the apparatus for doing small 2k spray jobs at home.

Thanks all.


Don't forget the before and after pics to show off your handy work! Thumb
 
  
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Marky911
Sepang


Joined: 04 Jun 2009
Posts: 2829



PostPosted: Tue Feb 04, 2020 10:33 pm    Post subject: Reply with quote

Yeah I bought the VHT paint and laquer last time, but when I began the prep I thought “Sod it” and took them to the powdercoaters.

I pay £30 for 4 calipers to be stripped and coated bright red. I then tried to use the VHT lacquer on top of the decals and powder coat but it wouldn’t set and I had to clean it all off.

So do it either way but don’t mix and match. A plus side of not lacquering over the decals is that when they discolour you just swap them.
I’ll be going for powder coating again if I get my current ones done. Never had an issue with discolouration but never say never I guess.

Glad you found the seal kits etc anyway.

Since you mentioned stuck bleed nipples etc. My mate Craig had one stuck in a spare caliper he had. He sent it to one of the specialists as they were refurbishing a set of good ones for him so he thought why not.

He got it back this with this comedy oversized nipple fitted. What a joke.
Grin



Another reason good to do things ourselves. nooo
 
  
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911Time
Spa-Francorchamps


Joined: 25 Sep 2018
Posts: 273
Location: Staffordshire


PostPosted: Tue Feb 04, 2020 10:48 pm    Post subject: Reply with quote

There's a joke there about big nipples but I'm not sinking that low Laughing Laughing

Looks like they had to retap it and fit the oversize one to sort it.

Did they also refinish the caliper in the picture? Surprised
_________________
Mark


I'm not a perfectionist - I just want everything done 'Right' Wink

Current: GT Silver 991.1 C4S with a few 'special bits'. Previous Owned: C63 Estate, BMW e92 330d Coupe (700Nm/Custom Exh/Map/BBK/Quaife/Breytons), ML63AMG, Alpina e46 B3S Coupe, Alpina e36 B3 Coupe, Lotus Excel SE, Alfasud Green Cloverleaf Ti, Lancia HPE, Capri 2.0S, Marina 1.8 (don't laugh it was my first road car). Bikes: Suzuki TL1000R and BMW R1100S AC Schnitzer.
 
  
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Marky911
Sepang


Joined: 04 Jun 2009
Posts: 2829



PostPosted: Wed Feb 05, 2020 12:40 am    Post subject: Reply with quote

Grin

Yes they had to oversize it basically. It’ll never go on a car we own though. It looks ridiculous.

That caliper wasn’t for refurb but they said throw it in with the ones that were and they’d sort the nipple.
I think they charged £50 for the privilege. Hand
If they’d said that would be the repair my mate wouldn’t have bothered. Grin

After seeing how the “professionals” do it, we’ve always done it ourselves since.
 
  
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infrasilver
Fast & Furious
Fast & Furious


Joined: 04 Oct 2010
Posts: 8560
Location: East Midlands

2001 Porsche 996 Targa

PostPosted: Wed Feb 05, 2020 2:55 am    Post subject: Reply with quote

I've always reurbed my own calipers, I use the Bigg Red kits, with VHT paint coated with 2k lacquer, they always come out stunning and very hard wearing.
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911Time
Spa-Francorchamps


Joined: 25 Sep 2018
Posts: 273
Location: Staffordshire


PostPosted: Wed Feb 05, 2020 7:05 am    Post subject: Reply with quote

Marky911 wrote:
Grin

Yes they had to oversize it basically. It’ll never go on a car we own though. It looks ridiculous.

That caliper wasn’t for refurb but they said throw it in with the ones that were and they’d sort the nipple.
I think they charged £50 for the privilege. Hand
If they’d said that would be the repair my mate wouldn’t have bothered. Grin

After seeing how the “professionals” do it, we’ve always done it ourselves since.


Unbelievable! Surprised Were those guys wearing chaps & spurs? Very Happy


infrasilver wrote:
I've always refurbed my own calipers, I use the Bigg Red kits, with VHT paint coated with 2k lacquer, they always come out stunning and very hard wearing.


Spot on! Thumb Smile
_________________
Mark


I'm not a perfectionist - I just want everything done 'Right' Wink

Current: GT Silver 991.1 C4S with a few 'special bits'. Previous Owned: C63 Estate, BMW e92 330d Coupe (700Nm/Custom Exh/Map/BBK/Quaife/Breytons), ML63AMG, Alpina e46 B3S Coupe, Alpina e36 B3 Coupe, Lotus Excel SE, Alfasud Green Cloverleaf Ti, Lancia HPE, Capri 2.0S, Marina 1.8 (don't laugh it was my first road car). Bikes: Suzuki TL1000R and BMW R1100S AC Schnitzer.
 
  
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wasz
Paul Ricard


Joined: 28 Dec 2012
Posts: 3072


1999 Porsche 996 Carrera 2

PostPosted: Wed Feb 05, 2020 8:13 am    Post subject: Reply with quote

I had a broken nipple once

I took it to a local engineering shop (the type that skims heads) and they mounted it in the mill, milled out the steel nipple, picked the thread out and clean up, and cut a new nipple seat. Cost about £50

You'd never know it was done. Unfortunately this takes skill and to know how to use tools, much easier to do the above and drill the lot out and fit oversize bits.
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My special order MY99 Vesuvious Charcoal 996 | Clutch, Fly RMS IMS AOS Job |
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911Time
Spa-Francorchamps


Joined: 25 Sep 2018
Posts: 273
Location: Staffordshire


PostPosted: Wed Feb 05, 2020 8:41 am    Post subject: Reply with quote

wasz wrote:
I had a broken nipple once

I took it to a local engineering shop (the type that skims heads) and they mounted it in the mill, milled out the steel nipple, picked the thread out and clean up, and cut a new nipple seat. Cost about £50

You'd never know it was done. Unfortunately this takes skill and to know how to use tools, much easier to do the above and drill the lot out and fit oversize bits.


That's the way to do it Thumb Some places just take the easiest route, rather than the right one - most times that's an attempt to save time and maximise profit but with this job it wouldn't really take any longer to do it right in the first place - if, as you say, you know what you're doing.
_________________
Mark


I'm not a perfectionist - I just want everything done 'Right' Wink

Current: GT Silver 991.1 C4S with a few 'special bits'. Previous Owned: C63 Estate, BMW e92 330d Coupe (700Nm/Custom Exh/Map/BBK/Quaife/Breytons), ML63AMG, Alpina e46 B3S Coupe, Alpina e36 B3 Coupe, Lotus Excel SE, Alfasud Green Cloverleaf Ti, Lancia HPE, Capri 2.0S, Marina 1.8 (don't laugh it was my first road car). Bikes: Suzuki TL1000R and BMW R1100S AC Schnitzer.
 
  
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Robertb
Dijon


Joined: 01 Sep 2003
Posts: 7587
Location: South Oxfordshire

2002 Porsche 996 Carrera 4S

PostPosted: Wed Feb 05, 2020 9:11 am    Post subject: Reply with quote

If anyone needs caliper decals I can recommend this lot
https://www.brakecaliperdecals.co.uk/Porsche-Decals/Porsche-Brake-Caliper-Decals

I fitted some a while ago, they were easy to apply and they have lasted very well.

I've not lacquered over them as the company say they don't need it. They may peel off in the end, who knows, but they give you spares and at £8.50 a set I'll just get some more!
_________________
"911- the guilt-free supercar"

Current: 2003 C4S Coupe, seal/black

Ex: '02 C4S Coupe, '96 993 Targa, '88 Carrera Sport Coupe
 
  
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UncleP
Monza


Joined: 27 Feb 2019
Posts: 168



PostPosted: Wed Feb 05, 2020 10:50 am    Post subject: Reply with quote

I've got 2 sheared nipples at the moment and 1 main pipe (the one that takes the fluid in to the calliper) that is stuck solid. All other nipples and pipes were a bastard to get off.

If I knew of an engineering shop near me I'd probably take them there to get done properly but I know of none and not the easiest to find.

My plan was to drill them out with a left handed drill and hope the heat and counter clockwise rotation brings the remains out. Failing that I'd try an eezy out. Possibly a bit over optimistic when we're dealing with galvanic corrosion but the temptation to drill is there as the remains already have a perfect centre punch to drill from. Not sure if sticking them in the oven for a while at about 150º would help before drilling.

Any tips welcome.
 
  
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Shalmaneser
Trainee


Joined: 11 Nov 2019
Posts: 70



PostPosted: Wed Feb 05, 2020 11:18 am    Post subject: Reply with quote

I've actually had good results getting nipples out of calipers by heating them on the radiator!

Any heat you can get into the metal will help with a stuck part I reckon, it can't hurt!
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911Time
Spa-Francorchamps


Joined: 25 Sep 2018
Posts: 273
Location: Staffordshire


PostPosted: Wed Feb 05, 2020 12:24 pm    Post subject: Reply with quote

A good machine shop can do in minutes, what could take hours at home but if you don't have one locally, then some pics would help identify what you have to work with.
_________________
Mark


I'm not a perfectionist - I just want everything done 'Right' Wink

Current: GT Silver 991.1 C4S with a few 'special bits'. Previous Owned: C63 Estate, BMW e92 330d Coupe (700Nm/Custom Exh/Map/BBK/Quaife/Breytons), ML63AMG, Alpina e46 B3S Coupe, Alpina e36 B3 Coupe, Lotus Excel SE, Alfasud Green Cloverleaf Ti, Lancia HPE, Capri 2.0S, Marina 1.8 (don't laugh it was my first road car). Bikes: Suzuki TL1000R and BMW R1100S AC Schnitzer.
 
  
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UncleP
Monza


Joined: 27 Feb 2019
Posts: 168



PostPosted: Wed Feb 05, 2020 12:47 pm    Post subject: Reply with quote

Only photo I've got at the moment. Old photo when they were still on the car. Can see they've sheared almost flush, both are the same. I'll get more photos tonight.
 



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