Replacement Brake Discs

[Chris Graves]

My 2005 Copen apparently needs new front discs. They have corroded, apparently because I don't brake often enough!! Local dealers have quoted £458.57 for supply and fit. They apologised for the discs being expensive but said they could only source them from Daihatsu as the Copen is so rare no after market manufacturers make replacement discs.

I have tried looking at the Japaneazi website but only get an error message, does it still exist? I've also had a trawl around online but could only come up with a supplier for the 1.3 Copen discs.

I really don't fancy forking out this much money unless I have to, as my husband can fit new discs and pads as long as we can get our hands on some.

Any help/info gratefully received.

[kirpen]

Hi
A competent engineering firm can often skim the discs. At the quoted price for new ones this is worth looking into. It is also worth checking whether 1.3 discs fit the earlier car, most of the chassis is identical.
K

[Japaneazi]

Hi Kerpin/Chris

Front discs i have listed on Ebay see item No 290366753452

I thought i still had these listed as i can still get hold of them. JapanEazi car parts website ive had to close down as it was just not viable im still selling a few items i have left on Ebay.

Dealers prices are simply rediculous.

Brake discs are the same for 660cc turbo and 1.3, some on Ebay list front discs as 234mm, these are wrong they should be 246mm.

I wouldn,t recommend getting your old ones skimmed as it weakens the disc even further than what they've been worn down to in the first place.

Regards

Tim

[Auds]

I had my brake disks and pads changed on Monday. Cost me £330 including labour for Daihatsu genuine parts. My garage said they look identical to the ones on a Nissan Micra but I thought I'd better put the correct ones on. They too tried to source them cheaper, but struggled. Eventually managed to save me about £20, but that was the best deal they could find. They told me it was the most expensive disks and pads they'd ever installed, and that includes BMWs and sports cars they work on!!! Everything's bespoke for these little cars.

[Chris Graves]

Thanks for the info everyone. Looks like the logical thing to do is pay a visit to Tim's ebay site. I don't fancy having discs skimmed as that will just make them thinner and speed up the day when eventually need replacing.

Fortunately there are plenty of sources for pads.

Once the job is done I'll just have to persuade my wife to use the brakes occasionally to stop any corrosion building up. Living where we do in rural Lincolnshire if you know the roads well you can frequently do your entire journey without having to brake. It always seems a pity to lose that energy that you've built up by burning expensive fossil fuels.

[kirpen]

Hi
I am also a "light braker" and have had problems with corroded discs over many years and many cars. Skimming is an option depending on the extent of the corrosion. There should be data for the minimum disc thickness and a decent engineering firm will advise. The problem is usually caused by sticking pads ( or pistons). I now always take the pads out every autumn and spring to clean and check that they and the pistons are moving freely and not seized. The Copen ones are better than most in that the pads rest on brass (?) bearers so that there is no rust inducing steel/steel contact between pads and caliper.
The worst conditions for disc corrosion are driving in salty slush and then not using the car for a few days. The rusting juice especially sticks between pads and discs. Once any significant corrosion starts it wears grooves in the pads which then won't polish the rust off the disc. It's probably worth hosing the discs with plenty of fresh water in these circumstances.
I also try to take the car in the winter when it is fine and drive a few steep hills and give the brakes a good work out. Also this year, as an experiment, I have made some waterproof covers to fit over the front wheels during the winter.
Fortunately the Copen has rear drums!!
K

[kirpen]

Hi again
I have just had pads off to examine/clean/lubricate before winter. I was disappointed to see that both discs were becoming very slightly rusty on the inside faces around the peripheral 2cm of disc. Clearly the inside pads were not rubbing properly on these outside edges. The rust is only light and superficial at the moment, and I am hoping that cleaning with fine emery, easing and greasing the pads, plus a bit of heavy braking will clean them up. The fact that the problem is identical on both sides suggests a design issue. I notice that the pistons, which operate the inside pads, do not contact the outside parts of these pads. This is the part of the pad which is not fully contacting the disc. In view of the price of discs I am keeping a close eye on the pads/discs.
Kirpen

[Bruce]

This is a re-call issue from Daihatsu and should not be charged for. I had mine done under warrnty a few months back.

[Gareth]

How did you find out about the recall?

I have a 53 plate that failed it's MoT year before last with the rusted discs (and worn bearings) - the replacement discs were nowhere near the cost mentioned at the start of the thread.

I use a local Toyota specialist for servicing these days so they won't of known of the recall but my original dealer has never been in touch.


(Next MoT tomorrow, so fingers crossed)

[kirpen]

Hi
I have just looked on vosa site and searched for recalls, but copen is not listed. Does anyone have info on recall?
I have also heard about a parts dealer called Blueprint/ADL who supply aftermarket parts for the Copen (and other more unusual cars/grey imports etc). They only seem to deal with the trade so the parts would have to be obtained through a motor factor or repairer who deals with this firm.
K