Installing Dust Boots into S Calipers

[tom1394racing]

I am finishing up the rebuild of my S calipers with the kit a bought through our host. I am having a hard time fitting the new dust boots into the groove around the caliper piston. It appears that the metal ring inside the dust boot is slightly larger than the diameter of the groove between the caliper and the piston and depends on a spring fit to stay in place. I was able to squeeze one boot into place, howver I bent the second boot while trying to force it into place. Is there a special technique to force the dust boot into place?

[Early_S_Man]

The only technique I know of is to make sure there aren't any dings on the edge of the bore from a piston bouncing off the other side from too much air pressure, then be sure to use silicone grease such as Dow Corning 4, 111, or 112 on the bore and seal before trying to install it. Never had a problem!

[joefrantz]

It's a close fit -- but then that's what you want.
The lube will make a big difference as Warren indicates. I've also used a c-clamp and a small square of 1x3 to press them into place -- the gradual, even pressure drew them right in.
Joe

[tom1394racing]

I'm not having any success. I tried the gerber baby jar lid and a C-clamp. Result was a deformed lid. I then tried a piece of 3X3 laminated plywood to apply more even pressure with my C-clamp. Result was a deformed dust boot. Not sure what to try next. Any ideas?

[luvndasun]

Hi Tom - I am having the same problem, how did you finally get the dust boots on?

[tom1394racing]

This was one of the most vexing tasks I've faced so far in the restoration of my RSR Clone.

I eventually got the second pair of seals I purchased (I ruined the first pair) to seat with lots of silicon lube, the 3X3 piece of plywood, a c-clamp and lots of patience. It's a job you can't rush.