Today's project: polished brake calipers
04-17-2005, 09:58 PM
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Today's project: polished brake calipers I originally intended to polish the calipers, paint the pad brackets body-color, polish the ZR1 wheels, and do a couple other small things. My approach was to remove casting flash with a Dremel, sand smooth by hand with varying grits of sandpaper, then polish the surface with a drill and 4" buffing wheel along with Tripoli compound.
This took FOREVER and I only finished the brakes on one corner, front driver's side. I didn't even get to polish the winter nastiness out of the wheel! It was dark outside so the pictures are a little off; I will take better ones tomorrow:
This took FOREVER and I only finished the brakes on one corner, front driver's side. I didn't even get to polish the winter nastiness out of the wheel! It was dark outside so the pictures are a little off; I will take better ones tomorrow:
04-17-2005, 10:47 PM
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Originally Posted by 777
i need new center caps for my formula's zr1's you know where to get them from>
04-18-2005, 12:54 PM
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Here are some better pictures taken in the daylight. Please excuse the water spots and stuff on the wheels, I didn't get a chance to polish them because the caliper took so long to do! I think I like the results well enough to finish off the other 3 calipers though, they really do look great behind the polished ZR1 wheels...
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04-18-2005, 01:49 PM
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Originally Posted by 777
the corvette ones...but the corvette part is peeling off and looks reall nasty...
The only reason I would replace them though is if the indention where the Corvette decal goes stands out too much after polishing.Thanks for all of the compliments guys! It sure was a lot of work but I think the results were worth it. When I do the other corners I will take some before/after pictures and do a complete write-up.
-Chad
04-18-2005, 02:32 PM
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That one caliper took about 6 hours total... BUT, this was my first time ever trying to polish one so I was trying different techniques that would sometimes reverse my progress. I had to go back over sections and fix the work that I had just undone several times because I would try something new and it wouldn't work. This time also includes disassembling and painting the brake pad brackets, back of the visible brake pad, and the rotor hats and edges plus re-assembling everything.
I'm hoping I can do the next caliper in around 2 hours, but I will be using some sort of machine to help with the sanding. Either a detail sander like the Black & Decker Mighty Mouse, or an orbital handheld sander or something... ANYTHING but doing it by hand! This was the most time consuming part by far.
I do intend to do the other calipers, and I will post a full write-up along with before and after pictures whenever I am able to find the time to do them.
I'm hoping I can do the next caliper in around 2 hours, but I will be using some sort of machine to help with the sanding. Either a detail sander like the Black & Decker Mighty Mouse, or an orbital handheld sander or something... ANYTHING but doing it by hand! This was the most time consuming part by far.
I do intend to do the other calipers, and I will post a full write-up along with before and after pictures whenever I am able to find the time to do them.
04-18-2005, 11:21 PM
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I used these instructions as a guide. Bambeezer did a great write up with pictures and a shopping list for supplies you will need. Make sure to have plenty of sandpaper, the aluminum calipers will chew it up pretty fast so you'll need to switch sheets frequently.
Just start the project slow at first until you get the feel for it...
I will say that I didn't have much luck with the wire wheel on the drill though. The coarse wheels I was using left some pretty deep scratches behind that had to be sanded smooth again later. The only thing I really liked it for was the heat extracting vanes at the rear part of the caliper. The wire wheel fit perfectly between the vanes and cleaned them up nicely.
Step #1
The Dremel with coarse sanding bands works great for removing the casting flash, just use a light touch and let the speed do the work. You could also use 80-100 grit paper by hand, but it will take longer.
Step #2
I started out trying to use 220 grit but the progress was very slow so I switched to 180. This worked a little better, but the progress was still very slow by hand with the rubber sanding block. Keep sanding until you've removed all of the marks left by the Dremel and you have the surfaces flat.
Step #3
Switch to some 400 grit paper and keep sanding until you get the marks out from Step #2. This will have the surface really smooth and bright. This was my final sanding step.
Step #4
Use the Tripoli buffing compound on your buffing wheel and drill and buff the surface to a high shine. It may take a couple of rounds, but it will definitely come out shiny. If you find any flat spots or un-even areas, go back and sand some more. Any areas that aren't smooth will appear wavy when polished. It won't look right at all...
Step #5
Use your favorite metal polish to put the final shine on your calipers. I actually skipped this step, and the shine is still amazing. The pictures really don't even do them justice. I'll try to capture some better reflection shots soon.
Just start the project slow at first until you get the feel for it...
I will say that I didn't have much luck with the wire wheel on the drill though. The coarse wheels I was using left some pretty deep scratches behind that had to be sanded smooth again later. The only thing I really liked it for was the heat extracting vanes at the rear part of the caliper. The wire wheel fit perfectly between the vanes and cleaned them up nicely.
Step #1
The Dremel with coarse sanding bands works great for removing the casting flash, just use a light touch and let the speed do the work. You could also use 80-100 grit paper by hand, but it will take longer.
Step #2
I started out trying to use 220 grit but the progress was very slow so I switched to 180. This worked a little better, but the progress was still very slow by hand with the rubber sanding block. Keep sanding until you've removed all of the marks left by the Dremel and you have the surfaces flat.
Step #3
Switch to some 400 grit paper and keep sanding until you get the marks out from Step #2. This will have the surface really smooth and bright. This was my final sanding step.
Step #4
Use the Tripoli buffing compound on your buffing wheel and drill and buff the surface to a high shine. It may take a couple of rounds, but it will definitely come out shiny. If you find any flat spots or un-even areas, go back and sand some more. Any areas that aren't smooth will appear wavy when polished. It won't look right at all...
Step #5
Use your favorite metal polish to put the final shine on your calipers. I actually skipped this step, and the shine is still amazing. The pictures really don't even do them justice. I'll try to capture some better reflection shots soon.
