Brake day. I didn't finish, unfortunately. As always, removing the _second_ puck is always the hard part. Finally I fabricated a seal/clamp out of a big washer with a ring of inner tube rubber glued to it, and two 6x2x1/4" strips of heavy metal strapping to serve as a clamp. I had to notch one of them to let the pipe from the grease gun fit through. With two C clamps I could then clamp the seal into place yet still leave enough room for the other puck to come out. It just walked right out once this was done, using water pressure from the grease gun. I have thought about fabricating this clamp every time I've had to do this miserable job, I finally got around to it!
With the sticky caliper all apart I got all the rust sanded out of the parts (outside the seal) so the pucks would slide easily again. They fit nicely into their bores and will now slip out under gravity. The rubber parts were actually in fairly good shape. I'll still replace it with the kits', but I will keep the old rubber for jalopy use. I blew dry everything that I didn't want to rust and set it aside for tomorrow. A little WD-40 went into the acme screws of the clamps and the grease gun guts. (I need to get a big bolt so that I only need one C clamp for this operation.) I may want to paint the part of the calipers where the rubber water seal goes on. Perhaps this will seal better keeping it drier inside and preventing further rust? -- Jim
