 | Home > Maintenance & Modifications > Brake Caliper Inlet Machining |
 
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2238   
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Afternoon all,
As part of my rebuild I am modifying the brake pipe arrangement and am running braided hoses straight to the calipers with banjo fittings. I did this on the 90 project and it worked nicely, the issue with the 110 is that the calipers are not brand new (maybe a couple of years old) and although the electroplating on them is still quite good, they have obviously been machined with a spot face where the fluid inlet is. This area now has some surface rust which is no use for crush washer sealing of the banjos. Has anyone come across any kind of guided spot face cutter (I dont have a mill) which can clean this face up? Being an M10x1 port, there isnt really much scope for a guide bush or anything. I am sure this must be a fairly common need but struggling to find anything. Cheers, Steve 02' 110 TD5 Double Cab Rebuild Thread |
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1st Jun 2022 11:01am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17548 
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You might be able to use an M10 piloted counterbore, but avoiding chatter if running one hand-held might be an issue.
https://www.google.com/search?q=m10+piloted+counterbore |
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1st Jun 2022 11:10am |
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2238
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Cheers, that was pretty much the only option i had seen. I can see that i would be unlikely to get a nice machined face without using it in a mill though so sealing will be impossible.
Seems like i need a sort of piloted grinding stone. Cheers 02' 110 TD5 Double Cab Rebuild Thread |
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1st Jun 2022 11:59am |
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2238
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Might give it a go then. Have got some old calipers i can practice on without any risk.
I was worried about getting then clamped well enough in my fairly rubbisj pillar drill but with the calipers split it shouldnt be too bad. At least my front calipers are the ones with the port on the back rather than the end. Cheers Steve 02' 110 TD5 Double Cab Rebuild Thread |
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1st Jun 2022 12:32pm |
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| rustandoil Member Since: 08 Sep 2012 Location: Cotswolds Posts: 774  
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The "pilot" on that counterbore, will be undersize on the M10 thread...wont provide much if any guide
Last edited by rustandoil on 4th Jun 2022 8:51am. Edited 1 time in total |
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1st Jun 2022 12:34pm |
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| DSC-off Member Since: 16 Oct 2014 Location: North East Posts: 1440 
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Alternatively, a standard drill bit can be ground to give flat botton holes,
I've used flat bottom drills to flatten the bottom of holes made with a normal drill, just to take the 'V' point out. (In the video at 10:50) Critical for machining the caliper is holding it square to and concentric with the drill or cutter. |
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1st Jun 2022 12:40pm |
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| landy andy Member Since: 15 Feb 2009 Location: Ware, Herts Posts: 5790 
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Can you not get hoses with a male end, and not go the banjo bolt idea?
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1st Jun 2022 12:49pm |
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2238
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Surely if anything it will be oversize? Minor diameter of an M10x1 6H internal thread is 9.15 to 8.91mm. The first M10 piloted counterbore I clicked on has a pilot diameter of 10.5mm which i guess is intended for a tight M10 clearance hole. Cheers, Steve 02' 110 TD5 Double Cab Rebuild Thread |
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1st Jun 2022 12:57pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17548
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It might be possible to find a piloted cutter with an appropriate size pilot, or to bush the pilot spigot to fit the bore. An M10 piloted cutter will have a spigot to match the clearance diameter of an M10 bolt, not the minor diameter of an M10 thread. (I have edited my original post here because I did misinterpret eddie's post and consequently my initial post was irrelevant). Last edited by blackwolf on 1st Jun 2022 1:08pm. Edited 3 times in total |
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1st Jun 2022 12:58pm |
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2238
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Very true but using banjos just keeps it all much neater and a fair bit more clearance between the pipe and spring when on full lock at the front. I will keep this as a reserve for when i have ruined the sealing face on the calipers though 
Cheers, Steve 02' 110 TD5 Double Cab Rebuild Thread |
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1st Jun 2022 12:58pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17548
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Another option might be to use a suitably-sized Rotabroach cutter. It might be possible to centre the pilot in the fluid orifice in the caliper, or even centre the cutter on an M10 stub screwed into the hole if you can find a cutter with the appropriate bore.
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1st Jun 2022 1:01pm |
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| Mo Murphy Member Since: 01 Jun 2008 Location: Letchworth Garden City, Herts Posts: 2270 
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Given that new calipers aren't perfectly flat around the inlet port but a banjo will seal, I'd be inclined to just give it a careful wipe of a nice sharp flat file to clean the surface around the port up.
Mo The Land Rover 90 - Many are called, few are chosen. 50 Shades of Pennine Grey |
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1st Jun 2022 2:33pm |
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| jpboost Member Since: 13 Apr 2021 Location: Gatwick Posts: 377 
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Do you have a small/local engineering firm that you could use?
By the time you'd bought any bits you need, you may well find it'd be cheaper just to get someone with a mill to clean up the face. I'm all for buying tools and becoming as self sufficient as you can be, but sometimes it's worth subbing out things like this to someone better equipped. |
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1st Jun 2022 3:25pm |
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