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Burnzybubbles

My Christmas project...

Well i wanted to get a lot more done but the powers that be meant I only really got one small project done, I picked up some b6 S4 rear calipers and carriers just before I broke up for work, they where a good price but scabby and needed some attention.



I tried the soaking in vinegar for a good few hours but I chickened out as I didn't want to weaken the metal in the handbrake mech spring due to hydrogen fracturing it did take some parts of the caliper and carriers back to bare metal but there was a lot of rust left to remove.





After going over with assorted wire brushes on a drill I then set about with some brush on caliper paint, I did the fronts with an aeresol can and the over spray went everywhere plus I didn't have to mask off using a brush.



In between getting the calipers finished I set about making my brake lines from parts from merlin motorsport, my aim is to run a 1 piece braided line from the caliper to the chassis, take the old brackets off and fix the new brake line properly with p-clips, my original thoughts where to make them as I'm fitting the brakes but I got impatient so used the measurements someone gave me when I put up a thread on here asking for the length of hose.





I couldn't be bothered with getting fiddly on the hand brake brackets and nuts and bolts so I left them to soak in vinegar for 2ish days, I was hoping to pull out sparkly parts but some where still coated in a crust of rust, I did find that getting the parts fairly hot whilst drying them out caused the rust to separate from the metal making it loads easier to remove ready for painting, I also used an aerosol caliper paint for these as it was easier.

Once dry enough I set about rebuilding the calipers, I removed the handbrake mech from the caliper housing and ordered a set of deep 90* circlip pliers to put the mech back in, after swearing for 10 minutes I realised I needed to compress the mech in the housing to give enough space for the circlip to sit in, I had to make up a tool using a socket and the caliper wind back tool, once figured out it, everything else was plain sailing

Got them back together this evening and even though they aren't perfect I'm happy with the results and will not only make braking so lot more stable as they compliment the s4 front brakes but they will also look better as you'll be able to see them unlike the standard brakes that are on there at the moment





Just waiting for the discs to turn up and get the right caliper carrier shims and I'll be good to go already got ebc red stuff to match the fronts so braking is nice and even.

Anyone else been upto much over Crimbo?
Burnzybubbles

Flickr fail images fixed now
Kent

Wow they look like new! This vinegar method you mention is interesting? Never heard of it. Bit like the Coca-Cola I guess?

I bloody love vinegar. I sometimes have chips with it.
Kent

Can't believe they are the same bits
rich86

Good stuff, I've done this recently. Have you got standard fronts?
Krister

Instead of winegar, I've used citric acid. You can usually buy it from a pharmacy store or super market. Pour it to some hot water and let it sit there. The rust is gone after a few hours depending how potend liquid you use and how hot water.


Link
Aragorn

Electrolysis works wonders. Did all my landrover parts with that. The stuff comes out looking actually new.
Burnzybubbles

Thanks for the kind words Kent your supposed to use white vinegar, but after soaking the smaller bits for 2 days and not seeing the improvement I wanted I'll probably go for another option next time, but yes it's a bit like the Coca Cola method if I'm honest.

Rich I'm running b6 s4 front calipers already, I've fitted them with redstuff pads as well hence why I've fitted them on the back

Thanks Krister and Aragorn I did look into these methods and I'll probably try them next when needed issue was space and time and I also thought I'd give vinegar a go as a few people rave about it, only thing that would go against me is they where soaking outside so the cold temperatures more than likely hindered the vinegar
suf3r

Quick questions, does stock R17 wheel fits if those rear calibers upgraded? How about brake disc? Also bigger right?
Kent

not that ive seen or done the cocacola method just a thing that you always hear about.

what would you recommend to use?

the citric acid sounds like a good alternative.
Burnzybubbles

Suf3r: the wheels should fit fine as the 345mm b6 fronts cleared the standard 17" Avus alloys albeit only just you just use standard b6 s4 discs and they are 300mm, but b6 s4 brakes are better than using the brackets with facelift calipers as you use b6 pads that are larger and cover all the friction surface of the disc, only problem is finding them in the first place and at a good price, all the information on fitting them I got from helpful members on here and mainly this thread...
http://audisrs.com/viewtopic.php?t=1807&start=0

Kent: yea the Citric acid seems a good choice but you have to be careful with certain metals as the acid dip can cause hydrogen fractures especially in thin or spring steel, you also have to neutralise the acid afterwards with an alkaline, electrolysis is good as you don't get the hydrogen issues but need the space to leave it working indoors and one or two 12v battery chargers for enough juice for it to work properly
suf3r

Burnzybubbles wrote:
Suf3r: the wheels should fit fine as the 345mm b6 fronts cleared the standard 17" Avus alloys albeit only just you just use standard b6 s4 discs and they are 300mm, but b6 s4 brakes are better than using the brackets with facelift calipers as you use b6 pads that are larger and cover all the friction surface of the disc, only problem is finding them in the first place and at a good price, all the information on fitting them I got from helpful members on here and mainly this thread...
http://audisrs.com/viewtopic.php?t=1807&start=0


It seems that not only B6 S4 have same calipers. A6 C6 (from 2005 to 2011 3.0T Diesel) also. In near future planning to upgrade front and rear from A6, just didn't find, if from A6 rear calipers would fit under standart R17 AVUS wheel's.
Planning to buy calipers from scrapyard, refurbish them, buy new rotors and maybe yellow pads... That's my plan.

EDIT: It seems that A6 C6 used electric stop brake (rear), so first thought of mine that it will not work on our B5 because cable is used instead...
Burnzybubbles

suf3r wrote:

It seems that not only B6 S4 have same calipers. A6 C6 (from 2005 to 2011 3.0T Diesel) also. In near future planning to upgrade front and rear from A6, just didn't find, if from A6 rear calipers would fit under standart R17 AVUS wheel's.
Planning to buy calipers from scrapyard, refurbish them, buy new rotors and maybe yellow pads... That's my plan.

EDIT: It seems that A6 C6 used electric stop brake (rear), so first thought of mine that it will not work on our B5 because cable is used instead...


Be careful as the a6 used different front brakes, it needs to come off a car with the 345mm front discs as they also commonly used 320mm discs, I had to send a set of calipers back as they used the wrong pictures, I never got round to what models certainly used 345mm calipers as it wasn't clear cut, but 2.7-3.0tdi models came with them as did the big petrol models, I ended up getting mine from Europe as it worked out cheaper.

The rear brakes are b6 only, I tried to cross reference on etka but it seems they are only specific to the b6 s4, can't remember if b7's used the same calipers but I know b8's used electric handbrakes so they don't work either, hence why I said they aren't easy to find, messages a s4 breaker on eBay and it looks like they sell as fast as they come in.
Noggymike

Nice work young man!

You Sparkies have far too much time on your hands!
Burnzybubbles

Noggymike wrote:
Nice work young man!

You Sparkies have far too much time on your hands!


Thanks, and I wish it was the case mike, I had so much planned and all I got done was these calipers
suf3r

A nice upgrade, but... look at god damn price for it :O
https://jhmotorsports.com/shop/ca...oem-p-314.html?cPath=21_56_61_241
Burnzybubbles

I'm not sure what you was supposed to link to as they are covers for the b6 front calipers, there prices seem ridiculous still, I haven't bothered with the clips as I'm not paying silly prices for a crappy bit of metal with s4 printed on it, and to be honest they look perfectly good without the b7 s4 clips.
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