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    Fall brake wrench time

    I am off of school for a week for Thanksgiving and just started a small project of replacing the brakes and cleaning up the suspension.
    This thread probably wont be very exciting. Just sayin'


    The list of things to do this week includes:

    -Grind down faulty drop hats so they dont rub anymore
    -Clean strut tubes and brake heat shields
    -POR15 the drop hats (will prevent rust where I grind them down), strut tubes, heat shields, and the area inside the strut tower that has been rubbed not so nicely by the drop hats, and any other misc hardware that I decide needs some love
    -Rebuild brake calipers
    -Paint brake calipers
    -New E-brake cables, brake hoses, pads, rotors and front wheel bearings

    Tuesday:
    I am not officially on my break yet but I will start anyways.
    I removed the struts, front brake calipers and front brake lines from the car and applied a fat bead of JB weld to the bottom of the strut tube (as if to make a generous fillet) where the strut presses into the steering knuckle. This should help avoid stress concentrations in that area and reinforce it. Im not expecting it to perform miracles in preventing what happened to danny's car but its not going to hurt anything and it's quick, easy, and safer than welding and heating the metal.

    The wheel bearings definitely dont roll nicely. The pass. side bearing groans on corners and the drivers side bearing sounds a little squeaky on the freeway between walls.

    Here are some "Before" pictures:







    This is the inside of the strut tower where the drop hats are rubbing (when making sharp right turns)






    The portion of the drop hats rubbing is from approx. 4 o'-clock to 6 o'-clock in this picture, this is what needs to be ground down a bit:


    That is all for today. I need to rent a spring compressor tomorrow and get everything cleaned up nice.


    oh, and this little buddy does a fine job at removing balljoints! It is deserving of a micro-thumbs up:

    Last edited by Sagaris; 11-16-2010, 03:51 PM.

    #2
    Son, I am disappoint. I was expecting to see a big brake upgrade, not a typo.

    Ich gehöre nicht zur Baader-Meinhof Gruppe

    Originally posted by Top Gear
    Just imagine waking up and remembering you're Mexican.

    Every time you buy a car with DSC/ESC, Jesus kills a baby seal. With a kitten.


    Comment


      #3
      Originally posted by u3b3rg33k View Post
      Son, I am disappoint. I was expecting to see a big brake upgrade, not a typo.
      This


      Would have been a win of a play on words too.....

      Comment


        #4
        Break. Brake. Good pun albeit accidentaly.

        Nice work. Should have sprayed underbody coating while you were in there! Clean everything up. That is part of my upcoming Spring detail.

        Comment


          #5
          No 'break' for you. Go back to school and study.
          -tim
          Originally posted by Jordan
          I like the stance
          -Coining hip terms since 10/9/03

          Comment


            #6
            Put the brakes on already

            Vinyl Lettering

            Comment


              #7
              How are you already on break? Thanksgiving isn't till next Thursday. You get more than a week off for Thanksgiving?

              Comment


                #8
                Originally posted by brokenbimmer533 View Post
                How are you already on break? Thanksgiving isn't till next Thursday. You get more than a week off for Thanksgiving?
                My school does trimester's so this week was finals week and I got lucky by having 2 professors move their finals to last week which left me with the rest of my finals early this week. So I am off until Nov. 29th

                Comment


                  #9
                  I seriously hope you're not studying Engrish......
                  Max

                  Comment


                    #10
                    Mechanical engineering, the bad english was intended.

                    Comment


                      #11
                      I have been working at a leisurly pace since it has been kinda cold and I have been occupied with other things but at this point. The rear calipers are rebuilt, painted with the new lines and pads installed and they are on the car. I tried sucking out the nasty old brake fluid from the lines with my fluid pump but didnt seem to get very much. The strut tubes have been cleaned, degreased, and painted in POR15 then top coated with semi gloss black. The drop hats have been ground down , painted with POR15 and topcoated and I have done some other random marts such as the sway bar brackets. The insides of the strut towers have been painted with POR15 where the drop hats had rubbed on them. Luckily only 1 spot was down to bare metal. The front calipers did not look safe to rebuild due to all the extreme pitting and rusty crud that couldnt be rubbed out so I bought some reman.'s from Advance. Either Monday or Tuesday morning everything should be buttoned back together with the strut bearings re-greased, new e-brake cables and be ready for bleeding.

                      I have Zimmermann rotors with Axxis Metal Masters. I couldnt find any helpful brake pad reviews. If you search for reviews on a certain pad, half of the reviews say "oh bro, those pads dust like crazy and have no cold bite, they only lasted me 1 and a half stops. I had to change them before I got out of my driveway" where other people will rave about how good those same pads were.

                      Struts with final coat of POR15:


                      With the topcoat:



                      Preventing rust from attacking the spots inside the tower that the stupid drop hats attacked:


                      My engine, because I like it:


                      Rear brakes installed with calipers rebuilt and painted "Cast Iron Gray"

                      Comment


                        #12
                        You need to do the following;
                        Lower it more
                        Replace your brakes with a big brake kit
                        Get Mtech Kit
                        Get BBS
                        :nice::nice:

                        Nah it looks good how it is. Nice Ride!

                        Vinyl Lettering

                        Comment


                          #13
                          I got things buttoned together today. I couldn't get the inner rear brake lines on, im sure I will tackle those later on when I do the subframe bushings, otherwise they look pretty nasty to get at. I bled the brakes twice with the help of a friend and took it for a test drive. The brakes felt weaker than before. The booster doesn't feel like it does much , it didnt before either but I was hoping that the calipers were just really stiff and that the pads were really glazed. The ABS light came on and stayed on. I checked the resistance at the front wheel speed sensors and its correct
                          the connections and wires appear good
                          and the sensors are clean ( I spent some good time cleaning them up) I also installed a new front pass side bearing (Timken) and it has the wheel speed sensor ring on it so it can't related to that. Is there any way to reset the ABS light? I took it out for another drive and with full brake force it locks up the front tires and the brakes feel more reasonable although I still think the booster is weak. The ABS pump ran below 5mph without impending wheel lockup but after hitting over 5mph the light turns on. Whatever.

                          Here are the pics of things cleaned up





                          After and Before

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