Lockheed caliper cap alternatives? Wax or Grease it!

As I stare at Peel project progress it popped to mind - can we come up with a Lockheed caliper cap alternative? After acy/oxy heat + dry CO2 ice puck with cheater bar, bone injury body slams almost removing the robust anvil vice that bent the hardened pins some as well as ovaled the tool and cap holes, which I got cleaned up + another more functional lightening set bored, I'd rather not put that heavy self fussing piece of work back on Peel. I see SS versions but shudder at risk of thread galling bind as brake sovent pressure weeps away normal anti-seize. Does it really have to be like a lid on a battle tank?

Re: Lockheed caliper cap alternatives?

one with a protruding machined hex instead?

Re: Lockheed caliper cap alternatives?

I made a special tool for an impact wrench and told about it in one of my first posts. Maybe can help?
newbie-restoring-mk3-first-post-t13675.html

JD

Re: Lockheed caliper cap alternatives?

Since the caliper body is alloy and the plug is steel heating the body should make it fairly easy to get it undone. Ive never had much trouble but
I realize that after 40 years it could be unmovable. Maybe if you take apart each winter or every few winters you would be ahead on the plug
as well as cleaning out the caliper.

Re: Lockheed caliper cap alternatives?

Ah so maddass but after what I faced on pre Peel and just about as bad on Trixie, whose cap did not move last attempt some weeks ago, on forks with oil vaporizing heat plus almost brutal torquing after prior good clean threads and lavish anti-seize used in false hopes again, I can only envision a proud robust bar all the way across to lever on. I've refreshed Trixies fluid about 2 yr intervals so twice so far. I think I'll be able to get Trixies off w/o breaking me or vise but its Ms Peel I'm interested in. Prolly cost most a $1000 to have one in Ti which may also be a binding bugger.

Re: Lockheed caliper cap alternatives?

try to remove with good fitting tool with hardened pins while caliper is still attached to bike, hold in firmly and good crack with a hammer.

Re: Lockheed caliper cap alternatives?

I have a home made tool that I got with my bike that does the job. It is an ~18" section of 3/4" steel pipe that has a light upturn in the outer two ends, from a third out. The center section has two steel pins welded onto it. Works a treat.

Sorry, it is at home, so no pics.

Re: Lockheed caliper cap alternatives?

The secret is in using the right tools. If you got a steel disc of 1/2 plate, and drilled it to match the plug, welded a 4 feet long bar to the disc, then drove in the correct high tensile pins into the disc you have made [ don't weld them or you may stuff up their tensile strength ] , you could have ended up with the correct tool. Now that you have made the tool, you will have to clamp it to the caliper in such a way as it cant dislodge itself while you are using a gorilla to pull on the handle. Sorry have to be funny here but can't think of anything better for this job.
go for it Hobot.
Dereck

Re: Lockheed caliper cap alternatives?

try to remove with good fitting tool with hardened pins while caliper is still attached to bike, hold in firmly and good crack with a hammer.

Click to expand...

Are you kidding me maddass - I've got skewed/bent short hardened pins that oval-ed out their tool steel holes which requires exquisite square on accurate body slam impacts not to loose the loose pins. Just plain 4 ft levering slid and lifted end of heavy 1930's wood desk full of stuff. Yoose guys ain't talking same level of the tight *I so fear to face again*. Its one of the events that makes me believe in mind over matter as it only let loose after I'd finally cried on 3 other lists for options it magically worked after a week of escalation, one a trip to town for dry ice. No bike unless fastened firmly to the floor could of withstood this scale force and retain upright and not good enough access either and might of tipped over a hydraulic lift stand not nailed down. It didn't just break free either but fought me the whole way to beat my mechanic sense of self worth in the trash. So truly my post is a serious plea for help rather than a luxury upgrade. I was left broken and bleeding in heart mind body over it.

Merely suggesting a bigger tool is not helpful, can yours bend the hardened pins? have ya run into cap so suck its resistance could bend the pins? I was able to apply such force, ugh, so I hoped to learn of alternate caps to ease this occasional mean task. Its a serious and emotional issue to me, one of a number events I wanted desperately to be rid of the clunker but thought I'd get more if at least roadworthy. I tease thee not, summer 2002.

Re: Lockheed caliper cap alternatives?

Hi Steve try this. I did this for a caliper that I found online cheap as the owner couldn't get apart.
If the holes are trashed in the cap, drill them out oversize, tap a thread into them, countersink the top of the hole.
To remove the cap, thread in longer bolts, us a long screwdriver or short prize bar, perhaps heat a bit with a heat gun, then remove.
Once removed and ready for replacement, do the reverse with the bolts, dress the thread with some sort of never seize paste, remove the bolts, put in a couple of countersunk headed cap screws to finish the job.
See pics below
Regards Mike




I made this spanner for the caliper that has good holes in the cap

Re: Lockheed caliper cap alternatives?

Hi
Made this out of 18" of 1/4 flat bar 1 & 3/16 wide, with curve on end to fit clutch cover slot, the caterpillar paint job makes it work!

Re: Lockheed caliper cap alternatives?

Alrighty Brooking that is a solution I can relate to if the plugs don't fuse in place. pre Peels holes were not damaged beyond normal use and still functional if only need to twist as hard as ones others have dealt with. Not nearly as non-functional buggered as your view or would not of been able to bend pins removing. I had holes reamed a bit to clean up looks but did not open them up any more. Bulldozer paint color tool reminds me of bulldoze shop press needed on swingarms which topped stress loads of the caliper cap. I guess I should search up better anti-seize instead of re-inventing the cap-plug. I regularly feel i've bitten off too much taking on Commandos.

Re: Lockheed caliper cap alternatives?

Steve, dont give up now, Lockheed didn't envisage that Norton didnt do their sums re ratios of master to slave , there fore whole caliper probably over heated during first 1/4 mile of twisties!!!
If you give up now , how the hell are we to be spectators to the maiden voyages of Mrs Peel!!!!

The bolts threaded into the cap give you so much "purchase" power!!!
Just don't drill all the way through.
Regards Mike

Re: Lockheed caliper cap alternatives?

I made my own tool with a disc of 1/2" steel plate with an old socket welded to it and some hardened pins. Having heard that the plugs can be tough to remove I attacked them with an impact wrench while still on the bike. While the big wrench had no problem with them they moved hard enough that I doubt that any wrench and bar combination would have worked without a lot of heat. There was no damage to the holes in the plug.

The multiple quick hits of an impact wrench seem to work better than slow steady torque. I learned that years ago taking inspection panels off airplanes. I used a 3/8ths impact wrench and hardened bits and rarely stripped a screw head while other guys used speed handles. Yes, I broke a lot of bits but I also was much more productive and drilled fewer screws.

Re: Lockheed caliper cap alternatives?

Brooking 850

+1 Did the exact same thing when I had to do mine, except I used a piece of angle iron for a handle. Worked like a charm.

Re: Lockheed caliper cap alternatives?

hobot said:

As I stare at Peel project progress it popped to mind - can we come up with a Lockheed caliper cap alternative?

Click to expand...

As you look at the progress of the extrordinary project, I might think the question would be, "Why am I using this Lockheed caliper?". :?

I guess your priority is going, not stopping.

Re: Lockheed caliper cap alternatives?

Pete I was shocked how hard Ms Peel could pull down better than my SV650 or Code's school Ninja I pressed - that stoppied too dam easy like slowing for blinds or a pull up short practice at gas station stops or pulling into our village square/test pad. Peel would throw me over the bars before she stoppied and try as I might I could not stoppie her more than 1/2" or then locked front up a dozen bike lengths into our test pad village square. Ever seen a stunt rider ride a locked front tire, I did a bunch of times before giving up on Commando Stoppie w/o something to hold me behind head light. Ms Peel had more capacity for everything than any modern but for acceleration and top end over 90 mph, which will be solved next time out I hope. The sculpted art deco Lockheed caliper looks so much better to me and is fairly light compared to modern replacements. With my hot nail mod even Trixie has more brake power that tire grip with 100 size tire, which I'm still miffed at list for the almost universal recommendation of that size so waiting to wear it out to put on 110 for more security. Peel's wave rotor is narrower than the single pad so only 3/4's of it contacts for friction, the rest over hangs rotor, so may slice of some the pad and drill holes in it too. Braking is way over rated as safety feature in fast cycling, especially on one as capable as Peel was on or off road. I will test Peel for 0-100-0 times to see where her pecking order lands, if I'm capable enough not to get hurt doing it. Peel is crash caged so someone else could ride her home for me. Just don't want to a mean fight to get cap off again.

Re: Lockheed caliper cap alternatives?

Hey Ho Ludwig - Peel's progressing but hope not over 30 yrs like yours took, which does floor us all with your vonder Commando results and Heavenly adventures. I really couldn't watch all the cobble stone sharp turn d/t groin spikes so salute your flight envelopes as well. Peel has more features than others so savoring the journey with constant delays d/t life's other secondary priorities. Last main thing to invent is overhead primary belt friction drive for [ugh 8 lb] 3 wire alternator behind barrels but must wait to pick up engine on Salt Lake trip in late Aug. Today I seal off frame fittings to see if it holds corrosive liquid and measure how much of the pickle juice it holds. Then solvent off a lb+ of remaining powder coat. Close to fitting Jim Schimdt's light wt. composite fork bush kit, mainly to take out bronze bush slack. I can see a few dozen more holes to drill. Maybe when I strip down to flat tracker/desert racer/parking lot stunter baseline might approach your lightness/power ratio. Someday will have details to chuckle at or drop jaws on.

Removed the caliper cap

I was able to remove a very stubborn cap (Plug, Caliper Body) by removing the caliper from the bike and placing the whole thing in boiling water for a few minutes. Then reattach to the fork mount and using a proper tool.
I made some hardened pins from an old 1/4" drill bit and steel bar.

The cap showed rust and corrosion on the threads.
The original seals were not leaking but the piston bores showed some hydraulic fluid staining.

Now, what is a good way to get the stuck inner piston out?
I've seen suggestions to drill a hole in the back side of the caliper in order to directly push the piston out, then tap and plug the hole. Other than aesthetics, any downside, like the new plug threads not holding up to the pressure?
Seems that an aftermarket piston design could have an internal thread cut into the concave side to allow a removal tool to thread into and pull on?

Re: Lockheed caliper cap alternatives?

If you're replacing the piston, you can do the same thing from the inside by tapping the piston itself and pushing against the caliper body. Worked for me!

As for the cap tool, you guys should think about picking one of these up:


I use them for everything from japanese bearing retainers to gearbox lockrings, etc... Great to pop in place, and hammer away on if need be. Bonus points if you get the ones with thread in ends as you can just make your own ends for them.