930 brakes redo (pics!)

[GeorgeK]

I am getting together all the parts for a brake upgrade:
-930 calipers front and rear
-floating front 930 discs and std rear 930 discs
-Dual Master cylinder pedal cluster (by the 901 shop thanks to the referrals on this very forum)
-All this mounted on a rebuilt suspension, based on Elephant and Wevo stuff everywhere
So first step, the calipers. This was not an easy quest, mingled with the necessity to buy parts for the ...930 brakes on our 1983 930 that had a rash of broken bleed screws. I managed to buy 4 calipers, all in rather good condition, but none as clean as I'd have wanted. So, a resto.
First the calipers, 2 front ones:



2 rear ones (thanks to Jeff Alton):




Then you start to clean them. The front ones were in fact painted black....over a layer of red. So stripper, more stripper, and complete disassembly. I used compressed air to blow the pistons out, which were thankfully in perfect condition.



Like in the Autopsy room:



Slowly going somewhere:

[GeorgeK]

The rear ones were much cleaner to start with but I hit a wall when removing the pistons. They were stuck. Big time. I managed to remove one piston, then had to use it a a press in the vise to start the others, filling the caliper with water. One caliper took me 3 *hours* to get the pistons out. Still all came out and were perfect.

When all is clean, I cleaned the threads. The guys at the hardware store now know every thread and pitch in Porsche brake-dom. M10X1 for the bleed screw, M12X1.5 for the bridge bolts:







Then, new bridging lines. Out comes the trusty Hazet flare kit:





(yes those are my wife's hands. She does that just as well as I do)
Presto!

[GeorgeK]

Now that all is clean and that the seals arrived (via Pelican), I can start the reassembly. New bolts and bleed screws as well.
The Patient:



Mid-way there:





And the fronts done, with a dab of paint on the bolts that are torqued to specs:



These will be on the receiving end of this:



A very instuctive project for me, and good for the peace of mind, now that all the components are as good as can be.

[Blanco]

You forgot the RED paint. Red means it will stop faster.

Good job... I will be following up on this to see rest of installation.

[GeorgeK]

Noah, yes on the Carrera.
Alex, Red?? Took me long enough to remove the red.

The rest will have to wait, as I am leaving for a year in Montreal. When I return, Wevo, brakes, thin glass, etc....

[GeorgeK]

Noah,
Good idea in theory, but no. My year there is for work, to make myself a better career when I return. The cars will take 2nd place by far for one year. Not that I won't visit you, Rick and a few other Pelicans in the area.
Plus when I return, I'll have my own garage under the house.
A few pics of the other work done recently, and the recipient:

[Blanco]

Originally posted by GeorgeK
Noah, yes on the Carrera.
Alex, Red?? Took me long enough to remove the red.

ahahah.. I know... hence the suggestion..

[NoLift911]

George - Nice setup

Can you tell me more about the dual M/C setup and what is involved in getting it in your car? Where you sourced and a cost?

Thanks,

-Jeff

[GeorgeK]

Hi Jeff,
The setup comes from the 901 shop in Florida. It cost (grab hold) 1600$. The fit should be a direct bolt in, with the lines to the original lines included. Actually the work is first class.
See these threads:
~for GeorgeK, 901Shop dual m/c~
Who makes Good twin master cylinder brake pedal clusters?

[}{arlequin]

I looooove that car more and more each time you post something about it George. When I saw your pics from last year (snow-covered mountain passes) after it was finished, I thought it couldn't get any better. It's better than anything from the factory!

[Bill Verburg]

Very nice!, keep the pics coming

[Emission]

Ooooowww. I wish I would have known beforehand... I have a bunch of 930 caliper seals/gaskets that are brand-new that I never used. I would have sold them... CHEAP!

Great pics with your write-up!

[adomakin]

Any more pics of your car George?

Andy

[}{arlequin]

George, can you post the length/thread pitch of the caliper through-bolts? What type of metal are they?

thanks.

[Jeff Alton]

Wow, I had no idea the calipers would cause you so much grief! Well, at least the price was righ!! Cool master cylinder set up.

Jeff

[NoLift911]

Nice setup on the dual M/C. I still need to install my BB kit and was wanting to go the dual M/C in my 84 Carrera. At least that would be one mod that would never need to be revisited if I decide to track and race the car in the near future.

George - isn't your car of early vintage? Would this setup bolt into an 84 Carrera? From the pics and the looks of my current pedal cluster it seems I would still need to do some fab work...


-Jeff

[GeorgeK]

Dave, the bolts that hold the caliper halves to the bridges are M12 (diameter)X1.5 (thread pitch) X 40 (length).
Jeff (catca), absolutely no grief on my side. I was decided on rebuilding whatever came, unless they were new in the box. Your rear calipers are *very* good, only the pistons were gummed up with a weird paste, that did also protect them very nicely. You are a good one in my book!
Jeff (nolift), my car is a '76, the last year without booster, a godsend for my purposes. For cars with the booster, the best setup (easiest to apply) seems to be the Smart racing unit.
A few pics:



Tightening the Wevo engine suport:



Gearbox support prep:

[}{arlequin]

thank you

[}{arlequin]

does it matter what kind of paint stripper is used to clean the calipers?

are some more damaging than others?

[GeorgeK]

dave,
I use stripper from a body shop supply store. It has not harmed the Calipers, the Fuchs finish.