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Tuning 1.25 16v Fiesta mk5/6


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We have a result😀 There has been a listing, on ebay, for the elusive drivers side St150 caliper. I snapped it up quicker than a fish that sees a worm on a fisherman's hook. I am now able to order the passenger side caliper too, from the same breaker, it is indeed a good day.😁 Decided to get the discs and pads separately instead of buying the kit with front, rear discs and pads together as it is ever so slightly less expensive, and I then got to choose a different style of discs for front and rear. They have two rows of drilled holes instead of just the one. The rear have a black coating that will eventually come off with wear.

Received all my other ordered kit today, in record time too. Ordered first lot on 26th, second lot on the 27th, and last bit on the 28th, it all arrived the same day🥴 Went to wilkos and bought some dot 4 brake fluid for the bleeding, it was only £4 so cannot complain one bit.

The repair kit looks good quality.

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Mintex pads and a set of front performance discs. 

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Can't wait to get the calipers and start to restore them, will be a fun project to undertake.

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I found this thread from the ford fiesta page and thought I would put a post out there, to put my pennies worth in😆 It's always a good thing to have other people's opinions and pointers with tuning up

Can anyone give me their opinion on whether this sports cat manifold is the same shape as a ford fiesta mk6 2002-2008. It says it is for mk6 2008-2012, how much difference do the two exhaust mani

That caliper paint will be the last thing left of the car when the time comes! BTW be careful using compressed air to remove caliper pistons. Once it goes, it will shoot off like a bullet and cer

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I have been very fortunate to have been given an offer from an ebay breaker for the rear end brake setup, of which was accepted in a heartbeat. 😀

The original listing was for complete rear axle with brakes included but have asked the merchant to remove the bits I needed, as to get rid of the axle that is unused would be a nightmare.

The original listings postage was also a massive £45 alone so with breaking it into smaller items has reduced shipping cost greatly to £10.😄

The brake discs that come with the kit look fairly new, so can imagine the pads may be that way too. Will be getting a caliper repair kit for the rears too, and buying new mintex pads with performance disc setup also.

Whole setup for rear, with postage, will be £90.

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5 minutes ago, zain611 said:

Nice one 👍. Good also you were able to get the seller to remove the bits off the beam. It's a heavy thing when me and dad got it for my car

It looks heavy, don’t think my mom would have a good time helping me lift it, lulz. Much quicker and easier to have them dismantle it before hand.

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Got the Hel, braded lines today through the post, very fast delivery from these guys. Have the bleeding kit, caliper spray paint, wire brushes, rust converter, dot 4, all that I need now are the calipers lulz.

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Yay finally got the front calipers today, a day late mind you, probably because DHL destroyed the box while couriering them about. Still they look ok and no damage; plus the bleeding screws are intact on these ones.

Took me absolutely ages to manually clean them up with a wire brush, a screwdriver and some Jenolite rust remover. The rust remover does the job but it is very intensive labour to get it done, have to keep applying with paint brush and working it around every five minutes. Not sure if a rust remover bath would be a better option; and just leave the calipers to soak over night perhaps.

I have the rear setup being posted today also so hopefully should get that lot here quick enough to start the restoration job on those. Will tomorrow have another go at removing the rest of the surface rust on the front calipers, there is far, far less on them now and they are almost down to bare metal again. Then it will be the paint job and new seals, pistons, rubber boots to re-fit.

Safety First Children

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Before

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After 4-6 hours hard work

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Managed to get pretty much all of the rust off these bad boys now with the aide of the wire brush attachments for a power drill. It took a fair amount of time to complete, and I had to fight to keep the drill in the place where I wanted to clean with wire brush, it was like trying to walk into a 100 mph wind and still move forward. My arms are aching like a good-un now.

 

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After finishing with the wire brush attachments the calipers were coated with hammerite Kurust, rust converter, this converts any last bits of rust to a paintable surface, it acts as a primer too.

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Received the rear brake discs today, and the rear axle kit the day before, had issues freeing the caliper carriers from the hubs as they were literally welded on with the rust. Eventually managing to free them, from the crusted calaboose, it was time to obliterate the scaly, corroded veneer. Positive thing was the discs came with some free drill mounted, poly scrubbers, for use to clean the hubs with.

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Working on the splash guards first of all the poly scrubbers where put to good use, de-scaling the rust in droves, they did an excellent job. Had to tap a few parts with a screw driver to knock off the heavily scaled corrosion, then re-scrubbed with the poly scrubber pads, and finally used the wire brush attachments to finish the job. I noticed that some parts of the guards had rusted through and there were miniscule holes, hopefully the primer and thick paint will help to bridge the gaps, I think they might be ok to use they still seem fairly rigid, but if not I have seen a pair new of guards for £30.

The left guard had been given a once over, removing the scales, the right one is au natural, and has not been touched yet.

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Managed to get most of the rust off, it is now only thin layer of surface rust to contend with, they have been treated with Kurust to start the rust conversion process.

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Kurusted

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Have the rear calipers and carriers in some rust remover, they having a nice long soak in the bath.

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Have finished restoring the externals of the front calipers today, and painted the rear disc splash guards.

Used a red high temperature spray paint with the calipers and used a product by hammerite to paint the guards.
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The guards are coated in underbody seal, this stuff is thicker than week old custard and is supposed to be able to withstand stone chips and impacts associated with the undercarriage of cars, so I think it will be a good coating for the guards, it will probably fill the tiny corrosion holes in too.

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I will be working for two days on Monday and Tuesday, this will give me an opportunity to leave the rear calipers and carriers to soak in the rust remover until Wednesday and then the restoration of those will commence. Going to clean up the under side of the hubs and give them a quick coating but will leave the bearings in as they seem to be fine.

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I started putting seals and pistons into the calipers today and have ran into issues. One of the new pistons has jammed inside the caliper and I can’t get it out either. I got the old one out with a can of compressed air but it won’t come out with that now. Will attempt to use my spray system gun to pump it out if the nozzle fits inside the hydraulic hose hole on the caliper.

The second caliper has accepted the old piston a lot more easier, it seems there may be an issue with the caliper repair kit.

I was using a caliper compression tool to put the pistons in and that was struggling so I can only assume the piston is slightly too big or there is a burr or something creating resistance.

I checked on the soaking rear calipers and rinsed them off and used a wire brush to remove the surface residue, it seems they may need slightly longer to soak to remove the extra rusty bits on the surface.

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That caliper paint will be the last thing left of the car when the time comes!

BTW be careful using compressed air to remove caliper pistons. Once it goes, it will shoot off like a bullet and certainly cause some damage to whatever it hits. Don't ask me how I know :whistling:😂.

A can probably won't have enough pressure, but a 7 Bar compressor probably will...

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2 hours ago, Luke4efc said:

That caliper paint will be the last thing left of the car when the time comes!

BTW be careful using compressed air to remove caliper pistons. Once it goes, it will shoot off like a bullet and certainly cause some damage to whatever it hits. Don't ask me how I know :whistling:😂.

A can probably won't have enough pressure, but a 7 Bar compressor probably will...

I did get the old pistons out with an air duster/can of air but the one I put in wouldn’t come out with the same can. I understand what you mean, it made a loud bang and flew out with force with just a can so with higher pressure I could see it being dangerous if the operator of the air was not careful.😮

I am wandering if the brake hydraulic system will have enough psi to operate the piston properly, to move it out and back in again?🤔

I have managed to put one new piston into one caliper and because I had issues, I put the original piston into the second one.

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Took the rear calipers out of the rust remover and although they had been in for a long time, they came out pretty good, but with bits of rust still on them. Not sure what I was expecting but the bottle says that it takes rust back to bare metal, and in my opinion that didn’t exactly happen. I got the wire hand brush on them and rinsed them in water, then got the power drill with the wire brush attachments on the go to polish them right up.

They  have now been painted with Kurust to convert the last bits of surface rust to a paintable surface like the front calipers were.

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I started to clean up the caliper slider, carrier brackets for the rear calipers today. I started off using a clamp to keep them steady but found I needed to pick them up to do hard to reach places.

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This is where the issues arose, because the carriers were so small my hand was very close to the vicinity of the area that was being cleaned, the gloves that were being worn only had protection coating on the palm side and were flimsy at best on the back side. This meant whenever the drill jumped it ended up on the gloves and my hands. The gloves were being chewed up, and being flimsy were also being twisted around the wire attachments. Not an ideal situation which turned out to be painful too. The carriers were eventually cleaned up nicely and all surface rust was removed as well as a bit of surface skin, lol😝

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Good olde elastoplast, recently I was thinking of being a shareholder with options to own stock.

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Coming together very nicely 👌. Like how you prepped the calipers for painting. I painted my rear calipers gloss black and need to do the front ones. Either might sand blast them then spray paint or just hand paint it.

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2 hours ago, zain611 said:

Coming together very nicely 👌. Like how you prepped the calipers for painting. I painted my rear calipers gloss black and need to do the front ones. Either might sand blast them then spray paint or just hand paint it.

Sand blasting defo a quicker option, probably easier too than using rust remover. I opted for spray painting just because I find it a quicker option, plus it was slightly cheaper for the can.

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2 hours ago, zain611 said:

Like how you prepped the calipers for painting.

I was experimenting with different rust removers to see validity and usefulness. Made a thread about rust remover, which was sort of linked to this project.

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Last can of caliper spray paint came yesterday and it was time to put it to good use.
 

Coated the rear calipers and brackets with glossy red pigment and will attempt to recondition the pistons and install the new seals when I figure out the best way to remove them.

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Finished with the rear hubs the other day. Got the poly grinder pads on the underside of them to get rid of the rust, cleaned them up nicely and finally used a wire hand brush to scrub off the rubbish that had clung to the wheel mating face of the hubs. Kurusted the heck out of them and then put some underbody seal, which again is taking forever to dry.

I'm not sure what it is with this underbody stuff it really is more like boot polish, but it is supposed to be of use in high traffic areas, where stones chips, and other impacts, and water contact are highly likely to occur. It is water proof , which is why I am using it instead of regular paint, so it will stop water from rusting the surface any further. Have also bought some new centre caps for the bearing housing which will left au natural.

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So I managed to get the pistons out of the rear calipers so I could replace the damaged seals. I had a caliper repair kit so decided to use the new pistons, which had their own issues when replacing.

There was an internal mechanism that needed to be removed from the old worn piston. This mechanism was locked into place by a round metal clip with three small oval shaped bends in it. I was recommended to use a pair of circlip/needle pliers to remove it.

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I managed to get a pair of circlip pliers and removed the ring inside the piston, not exactly with great ease. The circlip, needle, pliers did the job but were not the perfect tool.

When the ring got loosened it literally flew out of the inside of the piston like a compressed spring, which luckily made enough noise when it bounced off the cold, concrete, deck to allow me to locate where it had settled.

After taking the ring out it was fairly simple to pull out the inner piston mechanism and re-install it into the new piston. One was simple the second needed some persuasion.

Putting the retaining ring back in was a whole different, difficult, dilemma. The retaining ring did not have the usual two holes with a surrounding surface that could be compatible with the use of the pliers. It took much patience, and I mean a lot, to be able to prise, and then push the ring back into its place with a screwdriver, edging one side into the groove, and then the other side, being lucky that it didn't fly back out again(which happened multiple times).

Now need to wait for a new piston seal to come as one of the new ones got damaged when I tried to wind the piston back into the caliper. It is very fiddly to install the seals, and also very frustrating, they are not so durable and are easily split under the pressure of hand tools. 

I would really not recommend undertaking the repair process if you have no patience as this is a job that needs a lot of time, effort, and concentration. It seems sometimes like you could be taking one step forward and three steps back.

I am not sure if there are any speciality tools that are usually used by the re-manufacturers of caliper pistons, apart from rewind tools, but I would expect if there were then the job would be a whole lot easier with much less associated annoyance.

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Got the new seals and bearing caps today, fastest ebay delivery ever. Will crack on with trying to install the piston tomorrow and hope and pray that the seal stays intact. Have an idea it will be a bit more smooth of a job as I have a little experience now.

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Finished repairing/remaning the rear calipers today, greased up the last piston and installed the newly sent piston seal, which was way more simple now with some practice.

Just need to put the springs, bleed screws and pins on and jobs a good un. Had to put another layer of spray paint on as some of the paint got damaged during the process. 
 

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Hopefully tomorrow, weather permitting, I will take a look at putting the front brakes on, and also try to install the drive belt. I have been looking forward to doing this job now for a while but needed to wait for parts, weather, and time enough to do it. I am not back to work will Monday so if something does go wrong at least I have some time to figure out how to rectify it or get a professional to come and do the finishing touches.

Wish me luck😀

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Thanks for the luck, unfortunately didn’t get to do the work today😑 although it didn’t rain much it was still a little too damp, so I had a lie in instead, bought some workshop gloves from Halfords, and did some prep work on the rotors which saved me doing it tomorrow. 🙂

Sprayed a full can of Halfords brake cleaner over the two rotors to remove that horrible greasy stuff they pack them in. Have all the parts lying in wait downstairs ready for the job tomorrow. Gonna do it even if it’s slightly damp as I waited long enough to put them on.😁

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That’s the spirit one day to chill then go at it the next day fully charged no matter the weather 👍👍those are the best days working on a car seen me out with 3 layers on thermos on and water profs lol 😂

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