Caliper Rebuild Question

[aston@ultrasw.c]

My brake caliper rebuild is going nicely.

The only snag are the rear outer seals. I can not get them over the boss on the caliper body. When one side is down the other slides off

There is a beryllium copper(?) strip with little teeth that grip the boss. It looks good in theory, I can't quite seem to make it happen.

Any suggestions?

85
911
Carrera

[GaryDG]

Aston

I just rebuilt my 83 911 calipers by following the Pelican link http://www.pelicanparts.com/techarticles/911_caliper_rebuild/911_caliper_rebuild.htm.

Didn't have any issues except hard lines, one of which I had to replace.

I didn't understand your comment:

The only snag are the rear outer seals. I can not get them over the boss on the caliper body. When one side is down the other slides off

And the term Boss

Can you restate the problem?

[aston@ultrasw.c]

The rear dust boot seals the region between the piston and the caliper body.

I can get the seal to seat on the piston no prob...but step 2 is the tough part: seating on the caliper.

[LakeCleElum]

I just did a complete set on my '69 w//o problem. Maybe put the seal in a pan of how water to make it more pliable??????

[Hendog]

BTDT. I got the dust covers on using blocks of wood but I wouldn't say it was "easy". I've heard Gerber baby food jar lids do the trick nicely but I've never tried it; it just sounds right. Here's a link to someones solution The last post.

Brake Rebuild- Dust covers

[aston@ultrasw.c]

Originally Posted by Hendog

I've heard Gerber baby food jar lids do the trick nicely but I've never tried it; it just sounds right.

I figured it out - piece of cake when you know how.

The food jar lid gave me the idea. I got an 1 1/2 pipe fitting (end cap) which has an OD of 56.5mm. The wall was a little thick so I ground it down with the Dremel to give an ID of 50mm.

Perfect fit, one good squeeze and the seal is on!!!

Thanks.

[Joe V]

I found that a front inner wheel bearing race from my '84 Carrera is the perfect size to seat those pesky rear caliper dust seals.
Why I saved it, you ask? I thought it might come in handy for something. And it did!
Wife hates that!