Member Since: 21 Mar 2007
Location: Hertfordshire
Posts: 34
Yes, I agree. There’s still plenty in the brake fluid level. A little goes a long way. I’ve a fifty mile round trip today then it’s straight to the garage. I’ll post a follow up. Thank you 👍
30th Aug 2023 8:19 am
SamR
Member Since: 21 Mar 2007
Location: Hertfordshire
Posts: 34
Brake Pipes Corroded
Hi DN, I've had it confirmed today that it's defnitely the brake pipes. Does anyone know any workaround to fixing corroded brake pipes without getting the body off? Otherwise it's going to be expensive!
Any other things I should get done at the same time?
7th Sep 2023 7:24 pm
DN D3 Decade
Member Since: 24 Jun 2006
Location: W.London.
Posts: 2294
Hi SamR, It depends how far forward the pipes are corroded. Most are confined to the rear 1/2 of the car, and usually pipes are renewed from roughly above the centre (exhaust silencer area) rearwards, using pipe joiners, which involves flaring the existing steel pipe ends, and flaring (ideally) copper nickel replacement pipes, these would require quite complex bending operations to produce. Did your garage not offer a solution ? Body off, is really only necessary if all the pipes fwd of this are also corroded, or if you didn’t particularly want to have any joiners in the pipe work.D3 owned from new, P017 brake recall, BAS FBHIC, new FBH, LR013487 oil pump, new water pump. RRS front lower suspension arms. New suspension compressor/ relay. New Denso alternator. CuNifer rear brake pipes. New GKN rear propshaft. New HPFP belt & tensioner. New A/C Condenser.NO WARRANTY for many many years.
Last edited by DN on 7th Sep 2023 8:33 pm. Edited 1 time in total
7th Sep 2023 8:00 pm
SamR
Member Since: 21 Mar 2007
Location: Hertfordshire
Posts: 34
Hi DN, thanks for your further update. I think it is only corrosion from the rear. The garage hasn't actually seen it yet but they didn't think it was possible to cut the pipes and join them. Hence they said, basically it's a body off job.
How would I go about finding someone who was able to cut and splice them (Hertfordshire)? Is there a standard/good place to make the cut, you mention above the exhaust, so removal of exhausts is a minimum? I imagine it would save a lot of cost and time to try this as a first step. We've had the 2007 car (GS) from new and body removal sounds like it brings risk of further issues as well...
7th Sep 2023 8:31 pm
DN D3 Decade
Member Since: 24 Jun 2006
Location: W.London.
Posts: 2294
Hi SamR,
I don’t know of a garage offhand. But joining pipes is not something that is unallowable Car needs to be quite highly jacked up and supported at the rear, rear wheels off, exhaust system off from front of centre silencer preferably, heat shield above silencer off.
Click image to enlarge
Click image to enlarge
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The rearmost flexi and steel pipes on the rear suspension arms can be bought from advanced factors. Not sure if buying the complete steel pipes and cutting them to suit would be viable if you didn’t want to make your own up. I chose copper nickel, because I didn’t want to have to do this again, and steel ones will undoubtedly corrode again, although they probably would have outlasted my D3 D3 owned from new, P017 brake recall, BAS FBHIC, new FBH, LR013487 oil pump, new water pump. RRS front lower suspension arms. New suspension compressor/ relay. New Denso alternator. CuNifer rear brake pipes. New GKN rear propshaft. New HPFP belt & tensioner. New A/C Condenser.NO WARRANTY for many many years.
Last edited by DN on 7th Sep 2023 9:30 pm. Edited 1 time in total
7th Sep 2023 8:49 pm
SamR
Member Since: 21 Mar 2007
Location: Hertfordshire
Posts: 34
Thanks DN
Awesome Job!
7th Sep 2023 9:25 pm
SamR
Member Since: 21 Mar 2007
Location: Hertfordshire
Posts: 34
Hi DN, that advice was a life saver. My mechanic sorted it by splicing new brake pipe like you showed. Thank you so much. I owe you a beer! Im happy to make a small donation to a charity of your choice? 👍
21st Sep 2023 8:28 am
DN D3 Decade
Member Since: 24 Jun 2006
Location: W.London.
Posts: 2294
Hi SamR. Really glad you got it sorted Would you be happy making a small donation to this site ? Entirely up to you. Many thanks.👍D3 owned from new, P017 brake recall, BAS FBHIC, new FBH, LR013487 oil pump, new water pump. RRS front lower suspension arms. New suspension compressor/ relay. New Denso alternator. CuNifer rear brake pipes. New GKN rear propshaft. New HPFP belt & tensioner. New A/C Condenser.NO WARRANTY for many many years.
21st Sep 2023 9:07 am
SamR
Member Since: 21 Mar 2007
Location: Hertfordshire
Posts: 34
Hi DN, great suggestion. That’s done ☑️ 👍
26th Sep 2023 11:54 am
Flapper
Member Since: 04 Feb 2015
Location: Gloucester
Posts: 329
anybody know what size the pipe/fittings are? I see many different are listed.
26th Sep 2023 1:20 pm
DN D3 Decade
Member Since: 24 Jun 2006
Location: W.London.
Posts: 2294
3/16” pipe and 3/16” metric (M10 x1mm thread) fittings are used. The rearmost flares are DIN type. Where I joined the old and new pipes, I used a 3/16 joint with SAE type connectors, so had to use SAE flares there. If DIN joints/ connectors are available, ( they didn’t have them, where I bought from), you could of course use DIN flares here instead.D3 owned from new, P017 brake recall, BAS FBHIC, new FBH, LR013487 oil pump, new water pump. RRS front lower suspension arms. New suspension compressor/ relay. New Denso alternator. CuNifer rear brake pipes. New GKN rear propshaft. New HPFP belt & tensioner. New A/C Condenser.NO WARRANTY for many many years.
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Car needs to be quite highly jacked up and supported at the rear, rear wheels off, exhaust system off from front of centre silencer preferably, heat shield above silencer off.
Would you be happy making a small donation to this site ? Entirely up to you. Many thanks.👍
