Repaired a brake caliper

[Pete.]

A guy I know popped round with a problem for me today. He went to bleed the back brake on his bike and the stub that the nipple screws into came right off. Looking at it there was a crack almost right through and it was just holding on the last little bit (as evidenced by the dirt in the crack) so someone in the past has over-tightened the nipple. I wasn't sure it would come out great but I cleaned it up and welded the stub back on. I was worried that I might melt the small bit before getting enough heat into the casting but it went ok, considering my limited welding experience.
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a.k.a 'Geri'

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

[andys675]

well done, if it soesn't work you can always weld it shut and use one of those banjo bolts with a bleed nipple in, common on brembo calipers
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Some people feel the rain, others just get wet.

[dydey90]

[P.]

I know you have skills, but that is such a fiddly job... I have no idea where your patience comes from...

Turbo my GSXR now?

[kramdra]

Assuming it snapped in the thread, will the seat stay aligned.. will you re cut/tap it?

Dislike the idea of a welded calliper.. HAZ right next to the pot. Cool that you can do it, but I wouldnt use it. Mig or tig?

[Pete.]

It's all done, painted, fitted, bled and he's going to work tomorrow on it.

No HAZ issues since it's not anywhere near a loaded part. The threads were free and easy after welding and the seat lined up perfectly. To paint it, I bolted the halves together and popped the pistons in without the seals. They slid in and out free as anything so no distortion either.
____________________
a.k.a 'Geri'

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