Knock out pin removal

[falcn]

Items marked 13, 24 need to come out of the caliper bolt holes for these to go onto my 636 forks.

Any suggestions?

They won't come out when gripped by a wrench from the outside, already tried the dry-ice on them, no budge....

anything else?

[Jason 306]

Would some sort of oversized easy-out be able to somehow twist them out? I guess there's a ledge in there that prevents a punch from sliding down in there or a mini-slide hammer?

[falcn]

I have the Pit Posse wheel bearing remover which has split "cones" that fit into the inside of the bearing and expand when you smack a screwdriver like tip rod into the gap. This expands and grips the metal and works really well....for wheel bearings...kind of like a mini-slide hammer effect.

I tried it last night, and the knock out pins didn't budge one iota. There is no lip, the 10.5mm inside diameter is the same as the rest of the bolt hole bore.

[junglejim]

Maybe try PB Blaster or something like it. If all else fails get out the dremmel and cut through it verticaly (careful not to cut into the caliper). Then you should be able to colapse it and pull it out. Hope this helps.

[falcn]

Yeah I will try my PB Blaster - but don't think it is stuck because of corrosion or dirt, so I have low expectations of that working.

It will be very difficult to get to the inside of the pin with a dremel to cut it to collapse it (this is what I had been saving as my last resort).

[junglejim]

Thread it with a tap. Then you can put a bolt in it and drive it out from the back side.Its a long shot but mehh I've seen stranger things work.

[falcn]

That's not a bad idea. I believe for a 10.5mm opening it would have to be a 12.5 x 1.75 tap.

....or I could weld something across the opening and drive it out. If I had a welder....

If I had a drill press with vice I guess I could start drilling them out until thin enough to remove. I need more tools!!

[junglejim]

Originally Posted by falcn

That's not a bad idea. I believe for a 10.5mm opening it would have to be a 12.5 x 1.75 tap.

....or I could weld something across the opening and drive it out. If I had a welder....

If I had a drill press with vice I guess I could start drilling them out until thin enough to remove. I need more tools!!

Its a 12x1.75 or 12x1.5 will work in a 10.5 hole. If its soft enough material you may be able to use a 1/2-13 tap. Hope they aren't hardened steel inserts or tapping is out. You will ALWAYS need more tools!!! Yeah tig welding a plug in the end would work well. Good luck.

[falcn]

They don't appear to be hardened metal, I can surface dent them with my pliers.

[Expat]

You can get a cheap set of stud extractors at Sears, they have a left hand thread on them, use a tap wrench to screw the exractor in, it will bite and hopefully spin the bush as it is not threadded... can you apply heat? The alloy will expand much faster than the bush which will also help. Watch the seals though!
Good luck.

[falcn]

http://www.sears.com/shc/s/p_10153_1...stud+extractor

if you mean something like this kit, I don't think the brittle extractors will be up to the tast. Hell half the time i try to use them to remove stuck screws they snap.

[Expat]

Originally Posted by falcn

http://www.sears.com/shc/s/p_10153_1...stud+extractor

if you mean something like this kit, I don't think the brittle extractors will be up to the tast. Hell half the time i try to use them to remove stuck screws they snap.

Thats where the heat comes in. They have to be hard (which = brittle) to bite into the surface. They are made from the same steel as a tap or die, be gentle, they only snap if you are too heavy handed! (no insult intended!)

[falcn]

got a tap set from a friend. He had a good idea to expand on the tapping idea.

once tapped, use a short pipe, and a couple washers. Use the pipe as leverage against a nut to lift out the pin rather than knock it from the back side.

[falcn]

Well none of the above!!

I started to try and tap one, but it just started spinning.

I then took the caliper over to the workbench and figured, and thought "Well they are pretty soft metal..."

I got out my trusty cold chisel and put down some padding under the bottom of the side of the caliper and started hitting the side of the knock out pin. It started deforming and popped out of the bore!! I did the other 3 and now my calipers are knock out pin free!

I tested the alignment with the ZX6R fork leg mounts and they look SWEEEET! They line up perfectly.