The Begining

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I have refurbished the new 328 front callipers. They will be installed once the new trailing arms and callipers are ready.

Bellow are the greasy rusty front callipers.

Fully dismantled

After lots and lots of angle grinding & scrubbing & wiring brushing
The pistons still look in good condition.

Finished calliper, with new replaced rubber seal and dustcover, guide bolts & guild bolt covers.
I also have a full set of Goodridge brake hoses, Jurid brake pads & ware sensors, ready for installation.

I’ve also noticed that my exhaust is quieter when cold so there may be a small hole in my welds for the mid section of the exhaust. At some point I’ll need to take the exhaust off again and patch this. The exhaust has a fair bit of resonance between 2250~2900 rpm. Patrick applied some manifold wrap to the new section which helped a lot. The metal here is quite thin; when the exhaust is off I’ll weld some strengthening strips on.

The first stage was to remove the current callipers and disks. After spend a fair amount of time struggling to get large breaker bars in under the wheel arch to remove the calliper bolts, a thought occurred. How about turning the wheels so the bar can be used outside the wheel arch! Doh should of thought of that sooner. With the wheels turned it’s easy to undo the calliper bolts. The following picture shows the wheel hub with the disk and calliper removed.

Below are the fully restored callipers ready to go on:

After removing the disks and callipers from the wheel hub the new disks and calliper carriers were attached. The new brake pads were given a layer of copper grease in all the areas they contact the calliper to prevent any squeaking. With all the preparation done the old calliper and its brake hose were removed. (All the brake hoses are being replaced with Goodridge metal braded ones)
The new brakes hoses and callipers were connected to the brake line. With the brake pads installed the calliper was slid over the disk onto the calliper carrier. To get the calliper with pads over the brake disk the piston had to be pushed all the way in using a C clamp. Finally the calliper guild bolts were tightened to the correct torque setting. Below you can see complete right side:

This is the complete left calliper with brake wear sensor installed.

As there was not enough time to get on with the rear trailing arms the brake fluid was not replaced, this will be done once all the brakes are complete. For now the brakes were bled and the fluid topped up with standard dot 4 stuff.
With the above changes the brakes feel more direct/solid than before. I don’t know if there is any difference in stopping distance yet as I need to wait for the new pads to bed in.
Below shows the view is through the wheels, the new callipers are closer to the wheels than the original and they look shiny. Not much sign of all the work that went into resorting them.