Welcome to this weeks restoration. This week there has been a slight change of plan, Instead of working on the WRX rear end mechanicals i am going to be restoring a ruined set of Sumitomo rear calipers for my WRX seeing as i have already upgraded the front it would be a shame not to do the rears ( Link here- https://www.youtube.com/watch?v=_4d6kFOQFSA) So the plan is to fix the rust, clean up the castings, paint them, rebuild them and fit them to the car so lets crack on with the work.

First things first a visual inspection to check for defects or any major flaws that would render these calipers unsuitable for restoration and im pleased to say they are in good shape apart from being a little seized from sitting around for years.

The first job was to separate the worst caliper that had the piston missing as i couldn't remove it with normal methods so i cracked the bolts and separated the caliper showing me lots of corrosion in the ports so knew the piston would be locked in with corrosion so i knocked it out using a punch through the fluid inlet ports and then removed the pistons from the good caliper using compressed air.

After the pistons were removed i separated the two caliper halves i then headed over to the parts washer to remove years of brake dust, brake fluid and general road grime this step is necessary to prolong the life of the blasting media and stop the blaster from clogging up with lumps of crud.

Once dry the halves were loaded into the blasting cabinet and given a good blasting this removed all rust and corrosion from the surface of the steel and left me with a pristine surface to paint onto.

After blasting i re-assembled the calipers so that i could grind away the rough casting marks left at the factory and smooth the calipers out so they would appear to be one single piece. This worked out successfully and allowed my to go to the next step which was as usual etch priming the surface preparing it for a following coat of high build primer.

The primer was left to cure them was wet flatted to give a flawless surface to apply my basecoat red onto. Once the basecoat was applied i made up some Subaru decals with my plotter and white vinyl and applied them in the appropriate location then gave them a good coat of clear to protect them.

While the clear coat was curing i set about re-plating the bolts as they were still in perfectly good condition all they needed was a little rust removal and a new coating of zinc and clear passivate and they are good for another 20 years at least.

After all that it was simply a case of fitting new pistons and seals and joining the two halves back together with loctite and the correct torque this was verified by using my fully calibrated Snap-On torque wrench.

And there we have it one set of calipers all ready to be fitted and to do some serious braking :)

Which so you prefer the Subaru single pot or the Sumitomo twin pots? Let me know in the comment section.

As always i hope you enjoyed this video and i'll see you again soon with another episode.

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#Restoration #Subaru #Brakes

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Subaru Brake Caliper Perfect Rebuild / Restoration - WRX Restoration Series