Problems with the FFS Hi Spec Rear Calipers ?

[saska]

Bob,
Quick question but are Mintex rear pads MDB1890 with 256mm/22mm disks ? Know about the various compounds std, 1144, etc.
Just removed the calipers and while there is plenty of meat on the pads they're badly brake fluid contaminated.
BTW thanks for all your work on this.

[DeeAitch]

There appears to be three types of levers, ....... a later modified one where the first few teeth on the ratchet have been removed and it may or may not have a longer lever ...... so even Lotus recognised there were some problems with the handbrake.

Bob

The later lever was available as a kit, Ref service bulletin 1993/14 which states that it was fitted to all (SE's) after Vin N6780 (May92). Part number on the box is A100J0188J but service bulletin says A100T0188J - take your pick!
Lever is longer, with a few teeth missing, and comes with a new mounting bracket, bolts, clevis assembly and a new gaiter.
I bought a kit at Donny a few years ago when it was said to be obsolete. However the Bulletin states that 'supplies of the early type lever & bracket will be run out ............'
Not sure what you get if you now order a new lever from Lotus?

[bobbrown]

Saska

Pads are the same for all the calipers the part number you have is correct for MIntex and they are the same as the Elise fronts if it helps

685563.jpg

SIZE: 77.5 x 65.7 x 14.3

[Brit-Car-Nut]

There appears to be three types of levers, ....... a later modified one where the first few teeth on the ratchet have been removed and it may or may not have a longer lever ...... so even Lotus recognised there were some problems with the handbrake.

Bob

The later lever was available as a kit, Ref service bulletin 1993/14 which states that it was fitted to all (SE's) after Vin N6780 (May92). Part number on the box is A100J0188J but service bulletin says A100T0188J - take your pick!
Lever is longer, with a few teeth missing, and comes with a new mounting bracket, bolts, clevis assembly and a new gaiter.
I bought a kit at Donny a few years ago when it was said to be obsolete. However the Bulletin states that 'supplies of the early type lever & bracket will be run out ............'
Not sure what you get if you now order a new lever from Lotus?

According to the current Price Sheet, A100J0188J replaces A100T0188J and A100J0020F and went OBSOLETE (20/12/04).

[alexg]

For info, Hi-Spec turned mine around in a few days when I sent them back to be rebuilt last year when the issue first came to light. So they seem perfectly capable of returning the calipers within the time frames stated unless we all send them back at the same time...

[mnemonix]

Hi folks, been a while due in part to redundancy and more recently, a slipped disc in my back so I haven't really managed to follow this thread as well as I would have liked...

Bob did email me a while back to find out my disk thickness which I wasn't sure of and unable to measure at the time but I did reply with as much info as I could.

My problem now is that I still have the original HiSpec rear calipers fitted to my car and I'm coming up for an MOT at the end of the month. Since they were originally fitted (by Peter Smith) they have always been difficult to pull fully on and have never actually passed an MOT - requiring me to ask Peter Smith's to 'fix' the problem, which I'm assuming meant paying them some money to fiddle around under the car for a while, achieve nothing, and then pass it on the sly so to speak. Well this time I can barely afford the MOT let alone any extra to get these damn things through the test, so does anyone, anywhere have any advice for me? Could be a trick to make em work more efficiently or a testing station in the Nottingham area who don't consider the handbrake to be terribly important, if you know what I mean I know there's nothing else wrong with the car.

The above is the most important thing at the moment as the worst case scenario is that I literally have to scrap the car at the end off the month simply because the handbrake won't pass an MOT, the tax is due too and I can't SORN it without somewhere to keep off road

In the long run, I notice that HiSpec now want the calipers returned to them for replacement... unfortunately this is my only car so that's out of the question. I also now have no off road parking to store or work on the car.

Finally, do the 'new' calipers actually have a usable handbrake? I don't mean one that 'if you pull it like a gorilla while standing over the transmission tunnel it just scrapes the MOT test', I mean one you simply pull gently upwards to engage like you do on any other damn car - can this really be so difficult?

Sorry for all that, just had a lot of issues to catch up on and desperately need some help.

Cheers,

Chris.

[bobbrown]

Chris,

You have a PM

Bob

[bobbrown]

Some of the calipers that have been returned to Hi Spec are being returned today, they did have a slight delay as they had incorrectly machined a small part that they have now corrected.
Those close to Dartford will probably get them back tomorrow, those further north may take untill Monday depends on the carrier.


Bob

[Dico]

I've just returned mine. £8.95 by Royal Mail 1st class, value up to 40 odd pound. Could have increased the insurance cover at costs between £12.50-£14.00, but this is the second time I've returned them so I couldn't be arsed with any extra outlay, what with the brake fluid costs as well. I've no problem using my own time but feel sorry for the folk who have to depend on garages etc to dismantle the calipers.
Good effort from Bob. Poor effort from Hi Spec.

Posted them 24.6.11 at 12.30pm. Will let you know when they return.

[bobbrown]

It is marginally cheaper to send them via parcel2go, I tend to use DHL but used Citylink for the gear cables as DHL economy has a length limit of 120 cm plus you get to track the progress.

A word of caution please remove the levers and the handbrake cable adapters before sending the calipers back as we have already had one cock up on Hi Specks part sending the calipers back with the bits fitted to the wrong person.

Bob

[Dico]

A word of caution please remove the levers and the handbrake cable adapters before sending the calipers back as we have already had one cock up on Hi Specks part sending the calipers back with the bits fitted to the wrong person.

I did and I wouldn't expect anything less from them I even removed the bleed nipple plugs

[saska]

A word of caution please remove the levers and the handbrake cable adapters before sending the calipers back as we have already had one cock up on Hi Specks part sending the calipers back with the bits fitted to the wrong person.

That would be me. I Removed the cable adapters but not the levers.
So if someone who removed their handbrake levers has got their calipers back with my handbrake levers, I'd be grateful if you could get in touch. Email below works.
Need to get this sorted by next weekend (2/3 July) or the Serpentine Run is off and Roz will not be happy bunny.

[inkitin]

Need to get this sorted by next weekend (2/3 July) or the Serpentine Run is off and Roz will not be happy bunny.

Nor us

[Alan_C]

Got mine back this morning. I'd removed the handbrake cable adaptors but left the handbrake levers on and the bleed nipple covers, the calipers came back with what I'd sent them. The powder coating was peeling in places due to spilt brake fluid, my fault - after I'd removed them I put them in bags and essentially pickled them in thir own fluid. Doh! I was hoping they'd strip and recoat them, but that was wishful thinking! Now need to attempt to match the colour and touch them up. I'd be grateful if anyone has any idea what paint my be a good match, mine are red.

I won't be fitting these calipers for a few weeks yet as the MOT is about due and the current new rear standard calipers are working fine.
Once people start to refit these modified calipers, can you update us with how you feel the handbrake mechanism has improved?

Cheers all!

[bobbrown]

How many people have sent their calipers back as I have a feeling the take up has been relatively low.
If I have it correct there are still these on the list some I know about others not

1. paulwatkins
2. MPx
3. Ailwyn
4. Surfer Phil
5. Nige
6. Router
7. RichardK
8. ChrisB
9. mvf906
10. Luis Pinho
11. BigErch
12. AidenR
13. Tom
14. Mike k
15. vi11ain
16. mnemonic
18. alexg
19. whippit
20. ChrisP
22. Pit-Stop
23. Windy Farmer

If you have sent them and have them back from Hi Spec and are on the list can you remove you name as I am trying to keep track.

[saska]

How many people have sent their calipers back as I have a feeling the take up has been relatively low.

Bob, not on your list as you know, but to the rest: HiSpec had to make up a part which was incorrectly machined so they now know about this. Even so they got them back to me in 1 week & 1 day from the day they received them.
Think this is not bad considering it is HiSpec.

Once people start to refit these modified calipers, can you update us with how you feel the handbrake mechanism has improved?

Handbrake gets 3 clicks easily and will hold on a slight hill. 4 clicks takes a bit more effort but it isn't 'gorilla mode' and holds on a steep hill. This is on an S2 with long handbrake lever but even so if the buggers don't leak I'll be v. happy. Been driving the SE with good condition stock brakes but there is no comparison with the HiSpecs.
S2 with HiSpecs is currently in for MOT so we'll see what they have to say.

[bobbrown]

S2 with HiSpecs is currently in for MOT so we'll see what they have to say.

I will be interested in the results from the MOT as it should help on the following.
I did the change on Gazza's S2 today and they certainly feel better than the old ones.
I have been thinking about getting some new longer levers made up to reduce the effort on the handbrake lever so taking the ratio on the caliper from 2:1 to 3:1 this may not seem a lot but you have to take it in context with the ratio on the lever it's self so if the lever is 5:1 then the old lever gives a total of 10:1 and a new lever 15:1 which is more significant.
There is a cost to this that although I am happy to do the work, I can not carry the cost, I would think as a rough guide the new levers and new brackets are likley to be about £20.00 the pair(conservative estimate) which makes 33 pairs equals £660.00.
These will have a two fold effect one reduce the effort and two increase the travel so instead of 2/3 clicks it is more likley to be 4/5 clicks.
I'll see about making up some prototypes to test and go from there.

If you are interested in longer levers and are happy to pay for them then send me a PM and I'll start my own list rather than add another one here.

Bob

[RichardK]

Bob,
I'll be sending my calipers to them in about two weeks........

[RayD]

While I’d asked earlier if it were practical to extend the lever has anyone made sure it will move any further without damage?

It might be worth operating the lever with an adjustable spanner to get a feel for the effort involved and make sure it will effectively go further than the cable is currently taking it.

Hopefully it will … but it could be that 80% of the last notch is just stretching the cable.

Ray

[bobbrown]

While I’d asked earlier if it were practical to extend the lever has anyone made sure it will move any further without damage?

It might be worth operating the lever with an adjustable spanner to get a feel for the effort involved and make sure it will effectively go further than the cable is currently taking it.

Hopefully it will … but it could be that 80% of the last notch is just stretching the cable.

Ray

That's what a prototype is for, to check the fit and the operation.