Tricky Technical Problem!!Removing Seized Caliper Carrier Bolts. Ideas Please!!!

[s2dude]

more

[s2dude]

and more

[s2dude]

.....

[s2dude]

and yet more

[s2dude]

Mmm. dont try this at home folks

[s2dude]

Still got the caliper carrier in tact

[s2dude]

and finally...you will come out you little **************

[s2dude]

and out she came no problemo....

Though I would NEVER recommend trying this route unlesas all other avenues are gone!!!

Got looking at the other side with my Dad whos a bit of a DIY pro type and we ended up re grinding new flats on to the bolt and got it down to a trim 16mm with straight edges

Came off with a bit of persuasion from a breaker bar and by FAR the best route I could have taken.....The bolt was like new (only smaller and a few shiny patches!!!) and was totally rock solid in the socket luckily so this is without doubt the best way to do it if you still have an intact bolt head.

Just have to be very be methodical and precise so you take the right amount of each flat so you still end up with a symmetrical bolt......


I only wish I had done it on the other side.......

Grinding those disks was a total mare with a 4 1/2 " grinder and a 9" would be too big....very very tricky not to take chunks out of the hub or brake pipe so a lot of care was needed.

Also....the bolt would not pull through even with the head ground flush as there is a skirt on the bolt inside the carrier...had to grind a small amount of the flat caliper carrier face to get the bolt free....as can be seen in the solo pic of it above...though it's still totally flat and wont affect anything as its only about 1mm of material gone.

@ 5 hours ++ labour first side.... 45 minutes second side

[iain1067]

well done, reminds me of having a locking wheel bolt not come out, ended up going to a local eng firm who turned a bush to fit the bolt hole in the wheel with a hole down the centre so we could drill out the bolt head, worked a treat i still have the bush to this day just in case.


Iain

[s2driveruk]

well done, glad you're sorted out!!! Personally i'd clean everything up before re-assembly. I used hammerite high temp paint on my carriers and calipers and it lasted well for a good couple of years and hopefully you'll have less probs downstream

[s2dude]

well done, glad you're sorted out!!! Personally i'd clean everything up before re-assembly. I used hammerite high temp paint on my carriers and calipers and it lasted well for a good couple of years and hopefully you'll have less probs downstream

Thanks guys

Heres the little beauty of a bolt now

[s2dude]

and this

[s2dude]

As a sidenote what do you guys think to replacing the disk protector guards???
Mine are totally shot and Im thinking is it worht replacing them while Im there or is ther no great need for them and shall I just save the £18 + VAT per side iirc

[s2driveruk]

i'd say if you were going to uprate everything sooner or later then £45 would be better spent on new rs2 hardlines and the flexis than the guards, if keeping stock then i would get new ones

[s2dude]

i'd say if you were going to uprate everything sooner or later then £45 would be better spent on new rs2 hardlines and the flexis than the guards, if keeping stock then i would get new ones

Thats a very good point mate....Cheers

Im strongly considering get a Big brake Kit very shortly so will this mean that the Disk Guards will not fit???

Cheers