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PostPosted: Mon Apr 30, 2012 3:53 pm 
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Joined: Tue May 12, 2009 10:03 am
Posts: 378
Hi All,

I have a big problem. I have a Colnago C40HP with a Star fork. This weekend I decided to strip the frame for the first time in 9 years(I should have done it earlier I know!).
The front Dura Ace brake has become seized into the carbon fork. I'm currently trying a variety of methods to get it out and dont care if I destroy the brake in the process. Currently have pepsi sitting in the fork brake hole, hoping to eat into the corrosion. Before that I had GT85 sitting in there overnight and that didnt seem to do anything. Any other ideas?

BUT, worst case scenario, if i do destroy the fork, does anyone have any suggestions for a replacement for 1inch Star fork?


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Posted: Mon Apr 30, 2012 3:53 pm 


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PostPosted: Mon Apr 30, 2012 5:27 pm 
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Joined: Mon Jan 23, 2006 6:35 am
Posts: 5019
Location: New York
Try using some rust penetration oil like PB blaster.

For future so this does not happen aagain you can cover the brake bolt hole with electrical tape like super 88 by 3M.

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PostPosted: Mon Apr 30, 2012 11:04 pm 
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stella-azzurra wrote:
Try using some rust penetration oil like PB blaster.

For future so this does not happen aagain you can cover the brake bolt hole with electrical tape like super 88 by 3M.

I've got some GT85 soaking in at the moment. Hopefully this can help free it!!


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PostPosted: Tue May 01, 2012 11:59 am 
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Joined: Wed Apr 25, 2007 10:23 am
Posts: 692
Location: Pack filler
remove the pad holders, then turn the caliper anti clockwise.

Once thats done you can concentrate on the nut.
You'll be able to leave the nut soaking in penetrating fluid, then put an allen key in a vise and turn the fork to free off the nut.

Copper grease is a good solution to stop it happening again. :thumbup:

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PostPosted: Wed May 02, 2012 11:18 am 
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Joined: Tue May 12, 2009 10:03 am
Posts: 378
It came out!! For anyone else having issues, I first soaked it in GT85, then Pepsi, also poured boiling water on the brake stud a few times to try and expand and loosen it. It took 4 days of a combination of soaking and tapping with a hammer. Good news is that both the fork and brake are fine. I'll be putting electrical tape over the back of the fork hole to prevent all the cr*p getting in there.


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