Brakes pt.2
Brake jobs are just one of those things that takes way longer than you expect.
Dust shields removed. I dremeled off the small bits on the sides like suggested earlier to remove them without taking the hubs out. The only downside is that the bits cover two of the wheel speed sensors which might expose them to more heat.
One out of four media blasted. The front shields use screw head bolts instead of 10mm, those had to be removed with vice grips instead of a Phillips head to stop stripping them.
All four media blasted. It makes quick work of old chipping paint and corrosion.
This thing is great but could use a better hatch gasket, I was covered in dust afterwards.
Dust shields painted with rust converter and hubs treated with rust remover. Dust shields have no right looking this good.
Got the calipers back from paint but didn't get a good pic for whatever reason. I really wasn't too happy with the quality of work for what I paid, they discounted a bit afterwards but I could've done better myself with a cheap caliper coating kit. Poor masking and they weren't media blasted like I (ass)umed. They didn't want to do the lettering either so I did myself.
Lettering stripped and masked.
Done with gold VHT. The masking tape let some spray bleed through so next chance I get I'll fix the small bits of overspray with authentic hand-brushing. All in all, I think they turned out well regardless, just needs a bit more touchups.
If you bothered reading this part, my number 1 near-future wheel choice are the Advan RGIII 17/18 in racing gold which I think will match these calipers really well. I think they look fantastic on the NSX, very light, seem more creative than the normal brands, and not exorbitantly expensive. TSW Bathurst are my 2nd choice but they don't get me as excited.
Goodridge stainless brake lines to be installed. Perfect length and fitment and included all the hardware needed. The 10mm flare nuts were pretty easy to remove from the stock hardlines with a flare wrench and a bit of penetrating fluid, which is good since stripping them would suck big time.
Now's a good time to prepare the RR knuckle for the new sensor I had to order. The remaining head basically had fused itself to the car, absolutely zero chance of it coming out the easy way.
The hard way involves drilling, chipping, etc. until the sensor is no longer part of the hub. Kroger came in clutch to protect the driveshaft ABS ring teeth during the process. As long as the hole is kept the same shape and the mounting points are kept intact, the new sensor should still work just fine at the same distance from the ABS teeth. Labor intensive but the driveshaft didn't have to be removed.
What was formerly an expensive and hard to find sensor is now reduced to a fine dust. This, of course, is the only one discontinued in the US and no aftermarket one is available, so a new OEM one is on the way from Amayama. What would I do without them.
The car drives fine without the sensor BTW, at startup it stumbles a bit before it figures out the signal is missing and then the ABS/TCS lights come on and lets you drive normally. Neither of those are particularly helpful anyways according to quite a few owners..
Anyways, back to caliper rebuilds. I bought Centric seal kits and pistons all around and OEM pistons for the rears. OEM on the right. Could easily be reused in this condition, but the inside of the piston had quite a bit of rust inside and I didn't feel like cleaning it out. I measured both pistons with calipers and they were within +/- 0.02mm diameter and the same length so the dimensions checked out.
Centric/aftermarket piston boots on top, OEM on bottom. DO NOT BUY THE AFTERMARKET CALIPER SEAL KITS, THEY SUCK. The size of all the piston boot openings are way too small to use, it is impossible to fit them around the pistons when you're shoving them back in. I tried and tried and it never worked, even if you did manage it, the seal would probably be pulled out of the caliper by the friction against the piston. I had no choice but to reuse the old piston boots. They were all in good condition save for 1 or 2 small tears overall but I was super pissed to do that after all this work. This process was almost as bad as rebuilding my driveshafts, with just as much, err, "frustration outlets".
Rear pistons completed with new OEM pistons. Fortunately, all the other seals from the kit worked, including the square cuts, o-rings, and other misc. ones specific to the rear calipers. If possible next time I'd probably order the same kits for those seals and order the OEM piston boots separately and you'd still save money.
I found the closest readily available equivalents to the 3 magic greases Honda includes in their rebuild kits, Castrol red rubber grease and PAG grease for the slide pins to replace Niglube. We'll see how well they do during a future caliper rebuild with the proper seals.
Old rear hardware, couldn't find an easy replacement kit.
Now made basically new again. Centric makes a front hardware kit that's cheap and fits perfectly fine.
If the other stuff wasn't enough of a nightmare, I wanted to replace some "easy" brackets as well with new OEM and ended up snapping all the 10mm bolts off the knuckle, and snapped a bolt extractor into an old bolt. The other was drilled out and re-tapped to M6 with my new tap & die set and left it at that, I think one bolt is fine to hold a bracket for the hose...
Brackets mounted and EBC Yellow pads fitted. Normally pads are a quick replacement, but with the extra mils of paint on the bracket and pad, some had to be scraped off or the pads wouldn't slide freely in the brackets. Nothing's ever easy.
Calipers fitted to the brackets with completely new hardware (bracket bolts, pin bolts, bleeders, banjos, etc.). The extra cost is worth it to clean things up a bit and make future maintenance that much easier. The undercoating in the wheel wells is peeling off and looking drab, I plan to strip and re-coat it when I put in new coilovers to get more space to work.
This took a bit longer than anticipated since I had to reposition some of the new brake lines to eliminate twisting, so I loosened the flare nuts and made sure everything was set up to relieve any tension from the lines.
Finally time for brake bleeding. I had big and fancy plans for this, but I was very low on time and someone else needed the lift I was on so I enlisted a friend to help with the old fashioned way. I put a block under the pedal to prevent us from pushing it to the floor and potentially ruining a seal in the master cylinder, I'm good wish just destroying one or two parts during a project.
Fluid used was ATE TYP 200 DOT4, I'm sure it will be more than adequate for my purposes. Some friends use it in their dedicated track cars so good enough for me.
I had big plans for this thing, it took forever to find all the right fittings and hose sizes, and I had to modify the Ares pressure bleeder barb to a 1/4" fitting which is the only size readily available.
The red cap is a Motive universal bleeder adapter which is strapped to the master cylinder and just covers it with a large rubber grommet, I haven't tested how well it holds pressure yet. The blue Power Probe adapter is juuuuuust too small to fit snugly inside the master reservoir and the quick disconnect is 1/4" but doesn't hold pressure well with the QD fittings I bought.
I ended up wasting money buying all this stuff but hopefully can find a use for it during future brake jobs, I think it will work but I didn't have time to test it out.
Looking real good with everything back together, and with some proper wheels & coils they should fit the overall look even better. I'll do some touch-up on the paint when I go to replace the RR wheel sensor.
Oh yeah, and the performance is great too. No leaks (yet) which means I didn't unknowingly bugger anything up. I'm still breaking in the pads and rotors (EBC says ~100 miles street, then hard stops, then ~1000 mi total until full performance) but they grab much harder than the stock pads without being hard to modulate. The pedal travel is further before they start grabbing which feels odd but I read is normal from Kaz's blog after a full rebuild since the pistons slide back & forth much easier.
This took way longer than I thought it would, but I ran into a lot of issues with doing this for the first time on the car, not to mention all the work that went into restoring various parts. Future brake jobs should go much smoother now that everything is sorted and easily swappable without a dremel, drill, hammer, chisel, stress ball, what have you. Overall success but with lots of challenges along the way :wink:
Next up is fixing a few things like the sensor, front wheel bearings, adjusting windows, and also installing the GROM adapter and the new leather steering wheel & ebrake covers to replace the gross looking stock ones. After that, finally some new wheels/tires/coilovers to treat myself a bit, I'm getting a bit sick of what the car came with. Thanks for following along.