(very) stuck Allen key bolt (Bandit Caliper)

[mudcow007]

trying to split my rear caliper off my bandit an cant for the life of me get one of the big bolts that hold the sides together out

tried -

heat
lube
longer n' longer bars on the allen key for leverage etc..

its had bugger all effect, i have just left penetrating oil on the threaded end of the bolt to hopefully seep through...

anyone any ideas?

[SQL]

Impact hex key, its a god send

[map]

After a similar episode I went and got 1/4" hex socket set.

https://washford.scene7.com/is/image/Washford/168328?$PDP_MAIN$
yes, they were from Halfords. Only place open on the Sunday I was working. I'm sure other places sell them, probably cheaper.

Once you manage to remove remember before reassembly use of copper grease is your friend for next time.

Best of luck
____________________
...and the whirlwind is in the thorn trees, it's hard for thee to kick against the pricks...
Gibbs, what did Duckie look like when he was younger?

[SQL]

The amount of screws on the DT125 engine I had chewed up with the correct JIS bit ill add was amazing until I was given a impact driver its awesome

[mudcow007]

im sure i have got some of them hex socket thingies somewhere...

cheers will try an attack it tonight

[c_dug]

If it really is that stuck I would be tempted with the impact driver too rather than other methods such as bars on the end of allen keys, as the impact driver keeps the pressures in line with the hex head.

I find that when you add pressure from the side, especially using longer breaker bars, that is gets hard to keep the pressure square to the head of the bolt which can increase the chance of rounding in my experience.
____________________
I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[Pete.]

If you're trying to split the caliper because you can't get the pins out, don't bother. Drill the back of the pins and knock them out with a punch. Before you put them back in stick each one in your battery drill and spin them up and use a bit of emery cloth to clean the rust off them. Re-fit them with grease, not copaslip.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[mudcow007]

bit of an update

i left the caliper with one of our maintenance guys who has demolished the head of the bolt- he was only trying though

he said he knows someone at an engineers who will be able to get it out - i can see it being drilled an retapped....

Pete - its to clean the pistons up, i had to dremel/ cut the pins out as they were beyond stuck

cheers

[Pete.]

Pistons will come out without splitting the caliper.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[mudcow007]

ahh man really?

one piston is all the way out an the other is half way - so one is basically blocking the other one - that make sense?

i cant force it back in either - bad times!!

[SQL]

bit of wood in between em and use compressed air if need be

[Pete.]

Wrap a strip of cloth around a piston and give it a good squirt of wd40. Use the cloth like a shoe-shine buffer and clean the piston up. Get your old pads and jamb them in between the pistons. Lever between the pads to shove one piston or the other back all the way. Once you have one piston all the way home, put the old pad up against it and make a couple of wedges to fit either side to hold it in. Now blow the opposite piston out with compressed air, clean the piston, seal, seal groove up and re-assemble. Shift the pad you used to hold back the first piston to the other side and perform the same procedure for cleaning up the second piston.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[mudcow007]

top banana

will post back updates tomorrow

cheers Mr Pete, your a good un

[mudcow007]

Fixed!!

drilled the head off the bolt, which still didnt free off the bolt, turns out it was corrosion/ shite around the shank of the bolt, the threads were clean as a whistle

[gavcarter]

for future reference if a impact driver is not available use a T bar from a socket set ( not a long one with narrow handles ) put it under a fair amount of pressure and twat the top of it with a hammer ( as if you are trying to hammer the bit into the bolt) it a lot slower than impact driver but quite often works