[keithwbloom]

[Note to reader] I write both DIY summaries and project journals. The DIY summaries are literal, step-by-step guides to completing a project or repair/restoration on Passat parts, components or accessories.

The project journals are more a chronicle of a drawn out process, with all of my discoveries - and sometimes mistakes - laid bare in more or less real time. The journals are also a qualified step-by-step how to, but with "life" intermixed. I am not a made for TV do-it-yourselfer. I make it through projects unscathed sometimes. And sometimes I don't, working through obstacles and blunders, hopefully to a successful ending.

This thread is one such project journal. It has some mishaps, and an ample supply of frustrations. But the end result on this one is success.

[end Note to reader]

They're here! I picked these up from Godspeed last month. They are incredibly clean and, actually, nearly ready for refinishing. Little or no further prep work required. However to powder coat them, they will have to be disassembled completely, so I will have to blow the pistons out, strip the seals and screw fittings, etc. But all the parts are in very good/excellent shape, and it looks for now that I will not have to spend any monies on Porsche rebuild kits. :wrench:

So here they are in their "before" shots:

I know I have argued in other threads that solid surface vented rotors are better, but these are screaming, no howling at me for slotted and drilled 312mm vented discs. And probably EBC Red Stuff pads.

Or perhaps I will stay with PBR Deluxe Ceramics and get the calipers finished in Guards Red powder coat after all...

:lightsaber:

 

[keithwbloom]

Refinishing in progress

Hit the calipers and adapter brackets with high-temp primer (2000°F) and a color coat today. Will let them dry for a couple of hours and then it is into the oven for a cycle through curing stages. :wrench:

Preheating the calipers will help keep the paint coats from running and speed dry time before curing process.

I had polished one of the adapters and then decided to paint them both:

After a second coat of high-temp primer:

I returned the adapters to their original color from ECS, gloss black:

Then I suspended the calipers with floral wire again so I could spray all sides. Twisted some medium wire caps into the threaded holes for crossover connector and bleed nipples to keep paint from fouling. Wrapped the brake pad hanger pins to keep paint from fouling them as well:

One coat of high temperature primer:

Two coats of high temperature primer:

They look like spaceships in attack formation: :nerd:

So I was going to paint them Gloss Silver, but I had a change of heart when I saw how rich the finish looked on the adapters. So I switched to Gloss Black for the calipers as well.
First color coat applied:

Second color coat applied:

For now they are hung over the space heater in my workshop for the next couple of hours to dry to the touch, then I will cycle them through the oven at 200°F, 400°F and 550°F, 30 minutes each stage, with 30 minutes cooling in between.

They should be totally baked and cooled by midnight. :wrench:

 

[DerhsLacidar]

Digging the effective use of wire nuts, lol.

What paint and primer did you use for these? That black looks lush.

EBC Redstuff has always been a favorite for the sedan parked out front. :driving:

 

[keithwbloom]

What paint and primer did you use for these? That black looks lush.

Paint and primer both Rustoleum. Primer is high temp variety, requires oven curing for complete cohesion. rated to 2000°F. Paint is Gloss Black Caliper Paint, rated to 900°F but I am hoping to stretch that a bit with the high temp undercoat.

I am thinking EBC Red Stuff pads if for no other reason than the splash of color will look cool, but I know they stop like a vise. Do they dust a lot?

:wrench:

 

[DerhsLacidar]

Paint and primer both Rustoleum. Primer is high temp variety, requires oven curing for complete cohesion. rated to 2000°F. Paint is Gloss Black Caliper Paint, rated to 900°F but I am hoping to stretch that a bit with the high temp undercoat.

I am thinking EBC Red Stuff pads if for no other reason than the splash of color will look cool, but I know they stop like a vise. Do they dust a lot?
:wrench:

Funny, I just painted a pair of rebuild rear calipers with the same paint, except silver. Came out nice, but that black just looks nicer.

As far as the redstuff goes; They are on the front and rear of my sedan. I find that they dust a fairly good amount during break-in and then calm down.
The front tends to dust slightly more than the rear, resulting in going weeks between washes. I wanted a low dusting pad and these fit the bill.

Is a 17" wheel required for those Boxster calipers?

I have the a8 front upgrade and am thinking of looking into upgrading from that. The front calipers are old. The options would be to refresh them with new seals, TyrolSport bushings, sliders and paint them. My front rotors are not really the best. The second option would be a bigger BBK, but I don't feel like spending $1000+

 

[keithwbloom]

17" required. I am going to have to trade or sell my 16" OE Vancouvers that I use for winter setup (all seasons).

Actually surfing Vortex 5x112 classifieds now while I bake the calipers in the 400°F cycle.

 

[keithwbloom]

17" required. I am going to have to trade or sell my 16" OE Vancouvers that I use for winter setup (all seasons).

Actually surfing Vortex 5x112 classifieds now while I bake the calipers in the 400°F cycle.

Actually, I printed ECS fitment template and checked Vancouvers. They may fit after all with 12-15mm front spacers.

?


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[keithwbloom]

After air drying for 2 hours, there was a little bit of orange peel that hadn't leveled out yet:

Once they are fully cured, I will wet sand the orange peel areas and hit them with a single smooth color top coat so they are perfect.

Baking up a couple of sumpin' sumpin's for my Passat after the holidays:

Because the pistons were still in, I didn't cycle them through the 550°F stage yet. I have ordered the banjo-style brake line connectors so I can use the air compressor to blow out the pistons. Once they are removed, they will get the curing process once more with the final color top coat in place.

 

[hu vw]

Baking up a couple of sumpin' sumpin's for my Passat after the holidays:

Does your significant other know what is in the oven?:hmmm:

 

[vbora01]

:lol: I was about to ask the same thing! You know I was thinking about it last night after reading this thread, and I was like my parents would be pissed if I used the oven to bake some kind of car part, but then I was like as long as the car parts were on something it wouldn't be too bad.

 

[doyles-1.8T]

I'm just jealous you have this kind of time available.

 

[hu vw]

I was thinking about it last night after reading this thread, and I was like my parents would be pissed if I used the oven to bake some kind of car part, but then I was like as long as they were on something it wouldn't be too bad.

The car part or your parents?

Why does, "Just say no to drugs" pop into my mind?:hmmm:

 

[keithwbloom]

Does your significant other know what is in the oven?:hmmm:

Shhhh!

 

[keithwbloom]

I'm just jealous you have this kind of time available.

Keep in mind that I do these projects on spare or replacement parts so that I have no down time with the daily driver and I can take as long as I care to to complete each one. For the rear caliper refinishing, I picked up some salvaged Lucas rears from a 2004 GLX in a yard near my house for $25 each, and I have to date had them on my bench for about 6 weeks. Imagine the hell I might catch from my lovely wife if my daily driver was unmovable for that length of time.

That being said, I put up a good front that I have weak time management skills so expectations are artificially low, and I even sprinkle it now and then with a little ADHD boil-over. I like to think I manage my Passat time very effectively. When I am passionate about something, I can easily get hyper focused, and get a lot done is a short window.

There is a funny movie from years ago with Val Kilmer called "Real Genius", and within it is a character that interacts for the first time with a new student in the afternoon of his first day on campus. Later that night, she gives him a sweater she knitted for him during the interval since they met. I sometime feel like that character.

 

[DerhsLacidar]

Actually, I printed ECS fitment template and checked Vancouvers. They may fit after all with 12-15mm front spacers.

That would be good to confirm. I really like my mkV Biolines and the fact a matching spare sits in the trunk. :thumbup:
17" minimum means a 17" spare would need to be sourced.

That being said, I put up a good front that I have weak time management skills so expectations are artificially low, and I even sprinkle it now and then with a little ADHD boil-over. I like to think I manage my Passat time very effectively. When I am passionate about something, I can easily get hyper focused, and get a lot done is a short window.

:thumbup: This seems too familiar.

 

[hu vw]

Am I to assume the series of numbers on the calipers represents:

986 designates the vehicle model number

351 designates front calipers (352 designates rear)

421 designates left side (422 designate right)

shown as 986.351.421

Are the Boxster (986) and 911 (996) calipers interchangeable?

 

[keithwbloom]

The adapters I have are made to spec for the 986 calipers. I am not sure if the 996 calipers have the same offset and bores to accept the mounting bolts.


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[keithwbloom]

I know everyone is waiting for more SC porn — it's cumming — but I have to get the supporting cast members/fluffers ready first.

Added two more color coats to calipers after curing base coat and removing pistons. Wet sanded between and then polished top coat. Ready to reassemble with new piston rings and gaskets.

 

[DerhsLacidar]

I know everyone is waiting for more SC porn — it's cumming — but I have to get the supporting cast members/fluffers ready first.

Hmmm.... Interesting...:hmmm:

Can't forget the fluffers!

 

[keithwbloom]

Hmmm.... Interesting...:hmmm:

Can't forget the fluffers!

Roller Girl. Best fluffer ever.


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