Ok, I know there are plenty of threads dedicated to the R56 front brake conversion, but I have a question NOT covered.

So, I decided since my front brakes are about due for pads and rotors I might as well do the conversion. I found a local yard with a 07/2007 Cooper S be parted out. I scored the calipers, carriers, rotors, pads and stock rubber lines for $200.00

I figured before delivery the pads and rotors would be worn and worthless.... wrong, the invoice states the car had/has 5500 miles on the odometer when it wrecked. Visually inspecting the pads they are indeed about 90% and the rotors are still very beefy. The calipers themselves only have a small layer of brake dust on the front side, the backside (facing into the wheel well) are still shiny silver.

Anyway, the rotors are covered in a layer of surface rust, and I guess thats my question. How does one clean off this surface rust... its fairly thick (1 -2 MM)

I guess what I am getting at is I don't want to blow the dough on new rotors and pads if I can salvage these ones, I realize they are stock pads and rotors and won't give me the crazy stopping power of say EBC Yellow's etc., but again they are virtually brand new and I may as well use them until they are truly dead, but they have a surface layer of rust from sitting about 1.5 years.

Thoughts on how I should proceed?

 

WOW, Nate great find!

Few things I would do. rebuild the calipers because they have been sitting for over a year and the rubber as not been lubed by the use of brake fluid.
Might also think about painting them Red while they are off and easy to do.

The brake lines are not right. You will need the brake line with the R56 on one end and the R53 on the body side.

I'd take the rotors to the local parts store and have the guy with the most hours on the lathe give them a VERY shallow turn to get the rust off. Then wire brush the top hat and paint it before install for a new clean look.

I'd also take some sand paper to the pads before install. After install bed them in and enjoy your great find.

 

which Stainless line is the correct one? I have heard menton that all is required is simply a R56 set of front lines.

 

nope, the connection at that body for the R56 and R53 are not the same.

 

One last question. I started cleaning the calipers today and ordered a G2 kit to paint them. I am noticing though that the pistons on both calipers are at the full rest position rather than fully extended. I cannot move the pistons by hand outwards at all.... almost as if they are stuck.

Is this normal? I mean they are not connected to the vehicle and are sitting loose with the hoses still connected, there is still a bit of fluid escaping out the hoses but they are fairly dry. The hoses were NOT disconnected until the day I bought them last week, so they have essentially not had fluid in them for very long. The pistons are NOT rusted, and the boots are perfect.

Basically the question is can you move a caliper piston in and out by hand if the caliper is disconnected loose from the vehicle with virtually no fluid left in the lines? Will simply installing them on the vehicle, adding fluid and bleeding them get them going again?