Today at Atelier Kaz - ex-Honda R&D, F1, Indy/CART engineer

Started opening the calipers and had to inform the owner that I will need extra days.


Even for the late production model close to 2005, if the caliper service was neglected, there is very little chance of surviving without the rust getting inside the caliper.
This is especially true for UK based NSX even for the ones kept inside the nice beautiful garage.
For some reason, caliper overhaul is not included in the standard Honda service schedule on all Honda models in UK so I'm quite sure there are lots of cars with caliper issues on the road....
The MOT brake test equipment won't be able to spot this until the issue gets really worse causing big enough imbalance between the R & L sides.




Unfortunately, the rust managed to pass beyond the dust boot but fortunately, it was still just about start chewing into the edge of the piston seal that the caliper bore was fine.


Normally, if the rust reaches to this level and if the outer body looked dull, I would just send the calipers and brackets to the polymer coating company such as Bigg Red and have them chemically treated as well as shot blasted to remove and prevent the rust.

Because this NSX is fairly late model, the gold plating is still clean and looks nice (at least from outside) that not much point in sending these to Bigg Red as it will take several weeks.....
I just need spending extra time cleaning and checking the rust level.
Will apply my own know-how to prevent the rust going any further until next time the caliper is stripped and sent in for the polymer coating.




Obviously, none of the front pistons can be re-used as they were beyond the acceptable state.

Forgot to take the photo but the rust was also observed at the boot holder section of both lower slider pins so I may need to replace them as well.


As a comparison, the latter photo is from the recent caliper OH on my NSX.
The calipers and brackets are regularly serviced so not even a sign of rust on the piston wall.
No rust on the slider pins as well.




Moving onto the rear calipers.....


Kaz