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-   -   Campagnolo Chorus caliper "rebuild" tutorial with pictures (https://www.bikeforums.net/classic-vintage/799951-campagnolo-chorus-caliper-rebuild-tutorial-pictures.html)

Preynmantis 02-20-12 04:44 PM

Campagnolo Chorus caliper "rebuild" tutorial with pictures
 
Not sure if this actually qualifies as a "rebuild", but it was the best word I could come up with.

I am in the middle of my Canopus rebuild and I recently received the group that will get hung on the bike. As part of the group, I received a set of Campy calipers that needed some minor work. The more significant was the pads were well worn and hard, that and the calipers were a bit stiff and gritty in movement.

Being the adventurous soul I am, I decided to rebuild them while I wait on the frame.

The first picture shows the parts and caliper before use along with the tools I used (most of them). The LA's Totally Awesome cleaner is a wonderful degreaser for cleaning bike parts, it can be found at your local Dolllar Tree store.

http://i140.photobucket.com/albums/r...s/IMGP9140.jpg

The next picture shows removal of the brake pads since we will be replacing the inserts first.

http://i140.photobucket.com/albums/r...s/IMGP9141.jpg

The next shows the wear of the old pads vs. the new Kool Stop pads I picked up.

http://i140.photobucket.com/albums/r...s/IMGP9142.jpg

The first step to remove the old pad is insert a small screwdriver next to the pad and the holder...

http://i140.photobucket.com/albums/r...s/IMGP9143.jpg

... and twist. It starts to push out the pad.

http://i140.photobucket.com/albums/r...s/IMGP9144.jpg

You then continue to use leverage to keep puching it out. Some are really tight and others less so.

http://i140.photobucket.com/albums/r...s/IMGP9145.jpg

At the point that you have a bit exposed, you can grasp the pad with pliers and continue to pull it out.

http://i140.photobucket.com/albums/r...s/IMGP9146.jpg

A word of caution, these pads have a nut inside them that is just sitting there. Once it is exposed, it will just fall out.

http://i140.photobucket.com/albums/r...s/IMGP9147.jpg

http://i140.photobucket.com/albums/r...s/IMGP9148.jpg

http://i140.photobucket.com/albums/r...s/IMGP9149.jpg

To be continued...

Preynmantis 02-20-12 04:44 PM

Keep pulling the pad out until fully removed, repeat with the other side.
http://i140.photobucket.com/albums/r...s/IMGP9150.jpg

Use the degreaser to clean the holders. No sense putting it back together dirty.

http://i140.photobucket.com/albums/r...s/IMGP9151.jpg

http://i140.photobucket.com/albums/r...s/IMGP9152.jpg

The pads I bought did not have the notches cut in them to put in the retaining nut, so I had to cut them in. In this case, a good knife with a tanto point was important. Too bad Benchmade stopped making the Tanto Vex. I lined up the pads side by side and marked the new pads with lines where the notch would be cut.

http://i140.photobucket.com/albums/r...s/IMGP9153.jpg

http://i140.photobucket.com/albums/r...s/IMGP9154.jpg

Next I used a pair of dikes to cut the new pad along the lines down to the retaining groove.

http://i140.photobucket.com/albums/r...s/IMGP9155.jpg

http://i140.photobucket.com/albums/r...s/IMGP9156.jpg

I then used the knife to cut along the groove. This is where the tanto point helped out.

http://i140.photobucket.com/albums/r...s/IMGP9157.jpg

http://i140.photobucket.com/albums/r...s/IMGP9158.jpg

http://i140.photobucket.com/albums/r...s/IMGP9159.jpg

To be continued...

Preynmantis 02-20-12 04:46 PM

At this point, you should be able to just pop out the section.

http://i140.photobucket.com/albums/r...s/IMGP9160.jpg

Using the flat tip, clean out the bottom of the cut.

http://i140.photobucket.com/albums/r...s/IMGP9161.jpg

Checking for fit. I didn't make the cut wide enough...

http://i140.photobucket.com/albums/r...s/IMGP9162.jpg

...so I had to widen a bit. I prefer this to trying to figure out how to put some back.

http://i140.photobucket.com/albums/r...s/IMGP9163.jpg

Now it fits flush. This is obviously necessary to prevent the pad from bulging out in the center.

http://i140.photobucket.com/albums/r...s/IMGP9164.jpg

Now we start to put the new pad in. Wet down the pad and holder since water is a good lubricant for rubber. You can start the pad without the retaining nut.

http://i140.photobucket.com/albums/r...s/IMGP9165.jpg

Once you get the pad in up to the notch for the nut, hold it in place and continue inserting the pad.

http://i140.photobucket.com/albums/r...s/IMGP9166.jpg

http://i140.photobucket.com/albums/r...s/IMGP9167.jpg

Once in, align the holes in the rear. A little judicious use of a rubber mallet helps a bit here.

http://i140.photobucket.com/albums/r...s/IMGP9168.jpg

The fruits of our labors.

http://i140.photobucket.com/albums/r...s/IMGP9169.jpg

To be continued...

Preynmantis 02-20-12 04:46 PM

Now on to the calipers.

http://i140.photobucket.com/albums/r...s/IMGP9170.jpg

Remove the cable retaining nut.

http://i140.photobucket.com/albums/r...s/IMGP9171.jpg

Using an awl, hold the retainer and remove the nut. This one was a 7mm. A word of caution here, I lay out the parts as I removed them so I can put them back in order. Do something that will let you know how to put it back together correctly.

http://i140.photobucket.com/albums/r...s/IMGP9172.jpg

http://i140.photobucket.com/albums/r...s/IMGP9173.jpg

http://i140.photobucket.com/albums/r...s/IMGP9174.jpg

Next we remove the center pivot nut. A 14mm cone wrench was useful here.

http://i140.photobucket.com/albums/r...s/IMGP9175.jpg

Spin off the nuts...

http://i140.photobucket.com/albums/r...s/IMGP9176.jpg

...and remove the center bearing washer.

http://i140.photobucket.com/albums/r...s/IMGP9177.jpg

Pop off the main spring...

http://i140.photobucket.com/albums/r...s/IMGP9178.jpg

...and remove the center assembly.

http://i140.photobucket.com/albums/r...s/IMGP9179.jpg

To be continued...

Preynmantis 02-20-12 04:47 PM

We now have a disassembled caliper. Clean parts with whatever suits you. Once the grime is removed, I tend to use steel wool to clean off light oxidation from the washers and other parts.

http://i140.photobucket.com/albums/r...s/IMGP9180.jpg

Using a small dab of grease...

http://i140.photobucket.com/albums/r...s/IMGP9181.jpg

...lightly coat the wear surfaces with a light coat of grease.

http://i140.photobucket.com/albums/r...s/IMGP9182.jpg

Position the washer on the caliper arms, the grease will hold them in place.

http://i140.photobucket.com/albums/r...s/IMGP9183.jpg

Use the awl to center the washers...

http://i140.photobucket.com/albums/r...s/IMGP9184.jpg

...and reinsert the main pivot assembly.


http://i140.photobucket.com/albums/r...s/IMGP9185.jpg

Reassemble in reverse order, putting grease on all wear surfaces.

http://i140.photobucket.com/albums/r...s/IMGP9186.jpg

Tighten everything down and admire your handiwork.

http://i140.photobucket.com/albums/r...s/IMGP9187.jpg

Bianchigirll 02-20-12 04:59 PM

After you done cleaning them send them my way Ok?

AZORCH 02-20-12 05:02 PM

Great thread!!!!

Preynmantis 02-20-12 05:02 PM


Originally Posted by Bianchigirll (Post 13876882)
After you done cleaning them send them my way Ok?

But then my Canopus might feel unloved. I am not sure I can risk that.


Originally Posted by AZORCH (Post 13876892)
Great thread!!!!

TYVM

I stand in awe of the many tutorial threads I have found here to help me do the many things I have done. I thought I might add my humble part to the wealth that is C&V on Bike Forums.

buldogge 02-20-12 05:45 PM

Nice job...reminds me, I need to make some stainless conical nuts for a pair of Chorus brakes one of these days.

RobbieTunes 02-28-12 04:53 AM

Excellent tutorial.

Can't wait to see the "Magnum 'Opus"

That will be one killer bike.

Italuminium 02-28-12 11:58 AM

Nice work! Very kind of you to go through all the hoops of taking pics and writing a description.

gaucho777 02-28-12 12:10 PM

What, no video? ;) Thanks for the detailed pics and write-up!

Michael Angelo 02-28-12 06:42 PM

Nice work.


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