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rear brakes & Ears


rockinroyston

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A bit of progress made today.

Built up the disc & hub, 4 bolts (short heads) with loctite to 35 nm. This isn't in the manual (that I saw) which is why I left it off LOL. The bolts are non metric... the braking system does seem to involve a few non metric fixings... 

Took brake calipers off & added the spacer that I missed out. This had a knock on affect as the brake pipe now didn't align as well as it did. Got there in the end but I was verging on stripping the brass connector a few times... quite relieved when it finally engaged properly

Brake pads, made a bit of a cock up here as I thought the clips went on the outside of the caliper... they don't... Not much assistance from the manual in this area tho. I was also thrown by having lots of important looking black bolts in my pack. After a few confusing e-mailsphoto's between myself & Derek it became apparent I didn't need them as my calipers were already put together when I got them with suitable (not black) bolts in situ...

Rear flexible brake pipe: I'm glad I did this before doing the right hand side ears! it made access much easier. Could only put one washer under the end that goes to the chassis as with two the union wouldn't have tightened on the pipe. Had a head scratch re the locking nut on the other end & came to the conclusion it had to lock down onto the union. Again a non metric connection scenario involved here. & the nut holding on the union to the tube is non metric.

Doing the drivers side was much easier! On the near side I had waited until everything was in place before I torqued up (including the disc brakehub...). This made torque wrench access quite difficult on occasions! this time I torqued up what I could BEFORE I put the disc on... Loosely fitted the speed sensor which seemed to line up with the cog. Just received a replacement hub nut from Derek for the drivers side that is 41mm (same as the near side)... so now I don't need to buy a large 41.5mm socket which I will use once...

One point... I didn't want a repeat of my brake connection to the caliper issue again so I loosely bolted it in before I connected any caliper bolts at all. Obviously I had to be a bit careful when I slipped it over the disc but far easier than trying to bend pipes in situ...As mentioned before, because I'd pre set the dion tube up on the bench & not used the spacers on the caliper the brake pipe alignment was slightly out.

So next on the list... rear anti roll bar, hand brake cable, re do the brake pads, take the weight on the dion tube & torque up all the rear suspension nuts & bolts. & then maybe into 'soft goods'! But probably finish the wiring in the engine bay, final plumbing connections (now I have all the clamps I need), make a first attempt at bleeding the brakes. 

Without me really noticing I seem to have cracked all the main engineering construction tasks & I'm onto fiddly stuff in the next day or so... I reckon I've done about 10 to 15 hrs a week (including staring at my carreading manuals & Blogsfinding parts & drinking tea) & I'm in week 4 of my build.

 

 

 

 

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