The Brakes that Bind

I've been working on rebuilding the rear calipers, off and on, for about a week now.  It was frustrating getting the pistons out until I reread all of the published articles and used the adjusters.  Once the adjusters were out, things got simpler.  I realized that the pistons were seized in the cylinders because of rust around the outer edge of the cylinder.  This is what happens when brakes aren't rebuilt for 30 years.  To remove the rust I used emery cloth (the kind you clean copper pipes with before you sweat them) followed by some light oil.  There is some pitting left but I only needed to remove the surface rust to get stop the binding and I didn't want to have to sand forever.  I should probably buy rebuilt calipers but I'm cheap (on a budget).  Maybe eventually.  The first rear caliper I tore almost completely apart.  Meaning, the only parts that weren't disassembled were the guts of the pistons.  For the second caliper, I left the parking brake lever alone because there is nothing in there that I could replace. 

A few of my experiences didn't mirror what I'd read online.  Specifically, when it came time to reassemble the outer adjuster I found it easier than dissassembling it.  In one hand I had my circlip pliers gripping the circlip.  In the other hand I had punch with about a 3/16 diameter tip.  The adjuster, spring and top hat washer are already in place in the caliper half.  Using the circlip pliers and the punch I press down on the top hat washer just enough for the circip to wedge itself in the adjuster's bore.  Gingerly removing my tools, I grab my 17mm deep well socket and use this to press the circlip down into position.  You can hear a "click" when it seats.  Very nice.  The pictures give more detail than I can explain at 10:45.  Time for a Sam Adams before bed.  =)

Below the Surface

I always underestimate what I can accomplish in a weekend.  This time around I had what I thought was a reasonable list:

• pull the calipers off all four wheels for rebuilding at home
• install the new vacuum hoses
• set the idle; check the dwell and timing
• maybe even have time to check the valves

What did I accomplish?  I familiarized myself with my 914 and got a handle on what an endeavor this was going to be.  Don't get my wrong, I'll have a ball -- I love working on cars -- but this is my first vehicular restoration project.  Check out the pics to see what I'm in for.