Brake Overhaul - help me plan my steps to minimize downtime
 

Well guys its up to the next round of maintenance on my X5, shortly after my alternator dumped on me a few weeks back I realized I probably should address other systems on my car to ensure I don't get stranded again (and to get some of the age off my X5 at the same time) - thanks to Tim on the forum for helping me with my newly powdercoated lug bolts I also want to address the rest of the wheel/tire area.

Many thanks to the help of Stephen (StephenVA) our resident brake guru, I think I've narrowed everything down. I'd like to accomplish the following on this overhaul and get rid of my rusty rotors and dusty Pagid pads.

-Centric High Carbon E-coated rotors and new stainless retaining screws
-Power Stop Z17 pads and 2 new wear sensors
-Stoptech or ECS SS brake hoses/lines and a brake flush (last one was 2 years ago, and before that the last one was in early 2012)
-Parking brake hardware/shoes inspection, cleaning, and adjustment (I'm sure there is tons of grime on the back
-Caliper overhaul with fresh painting or powdercoat

The last part for me is the hardest, in talking with Stephen yesterday he assured me that my calipers although 13 years old are probably not driven hard enough to be "cooked" so I could probably get away with rebuilding the front and rear seals, and getting new ATE bushings and guide pins, and have many more years of trouble free operation.

I currently have a coat of G2 caliper paint on there, and have been happy with it, but thought to myself maybe I should have them completely stripped and powdercoated going forward.

Theres a powdercoater not too far from me in PA who would do my calipers and brackets for $50 apiece which is excellent - however they would like the calipers disassembled, which isn't a problem. Only thing I'm worried about is the downtime (about a week), but I guess I could accomplish all my other repairs during that week, and I need to double check with them that they want the dust boots and piston removed - I only worry about damaging the fresh powdercoat with grease or brake fluid if I have to reinstall the pistons on the newly coated calipers.

I am going to email them to be sure, ideally I'd like to clean the bore and piston and replace with new seals and have all other bushings and hardware removed and have them mask off the piston area when it gets powdercoated.

Alternatively, and I spoke to Stephen about this too, in order to minimize downtime, RockAuto sells Centric rebuilt ATE calipers for $36-40 apiece after core charge, I would still get fresh ATE bushings, guide pins, and seals (if the powdercoater requires the pistons removed) - so I'd be at about double the cost but less downtime.

3rd option will require 24 hours of cure time plus the prep work, but I could just do another coat or two of the G2 caliper paint on my calipers and skip the powdercoating completely.

I think I have the brake system covered, any thoughts on what to do with the calipers or the best way to accomplish all of the above? I don't have compressed air to get the pistons out but I have a bicycle pump or I could just take the pads out and pump the brakes to get the pistons out. With 89k miles and 2 flushes in the past 5 years, I'm theorizing that my pistons and caliper bores should be in pretty decent shape.

Breaking News: I got on their system and change your shipping address to mine :D :bustingup

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I would put another coat of G2 on the calipers though. Behind your multi-spoke style168, nobody can tell the difference between powdercoating and G2 paint.

I can almost bet they will ask for the boots to be removed, not 100% but more than likely. Sad cuz thats a great price for powder coating but I would stick to G2 paint.

On your concerns about the brake fluid on new calipers you can just have some quick detialer to clean them off along the way. Stephen helped me with one of mine while tricky we didnt impact the G2 paint on there at all and if your concerned i think you can wrap in towels or low stick tape to protect finish?

Like others, I wouldn't bother powder coating brake caliper.

Tam you are beating me to the punch! Should change your post to BRAKING NEWS lol - did you get the cross-drilled/slotted Power Stop kit?

Yes powdercoaters are asking for the pistons and seals to be removed - so I'd be assembling them and you're right unless I am making a large mess its probably not too big of a deal.

I probably wouldn't bother with just the calipers either, but I'm going to get my roof rails done and probably my spare set of lug bolts - so if I'm trekking down there for $50 apiece I may just get them coated.

The G2 paint is phenomenal but sets up super quick, I almost would want to get 2 kits so that I can take my time doing the fronts and rears at separate times. Last time when I was doing all 4 I remember rushing to get them done and the paint was setting up pretty quick in the can once mixed (and no the kit was not out dated)

Another $40 for an additional G2 kit but if I'm rebuilding my own calipers anyway and getting them coated its a $160 difference - not too much - but yeah I think I should just rebuild my calipers instead of doing core exchanges and buying rebuilt ones.

Don't forget to stock up on BMW Wheel Cleaner so you can get your barrels real good while you have them off. Will give you something to do while the paint cures!

Just me, but I wouldn't bother with powder coating them. Unless your coater is offering to grind/polish the castings smooth, including the carriers. For $50ea, I kind of doubt it, as it's labor intensive to prep them smooth. I'd paint them and be done with it; little to no downtime.

Yes Tim these barrels will be spotless! I actually am probably going to put a ceramic coating on my wheels when I do the brakes.

You guys are right - considering that I am going to remove and rebuild the calipers anyway while they are off, no need to waste time and money with powder coating. I'll set up and prep the calipers and carriers and get them all propped up on my workbench and do a proper painting job.

This way I can get them 98% covered and once they are mounted on the X5 with the multi spoke 20's on there like tmv said you won't even notice if a spot is missed.

When I painted the calipers with G2, I split them in half to do fronts then rears. Mix in half of the hardener with half the paint. You don't need a very precise mixture anyway. That way I wasn't rush through the job.

^good call I will def try to do that! Did you just put the seal back on the epoxy reactor and mix up later then?