EJ,
Thanks for checking in. Here's how it went this weekend (I cross posted this on a TT thread so forgive if some parts sound out of place):
Friday:
I jacked up the truck and tested cleaning the rotors with the wire brush drill attachment. Everything seemed a go for Saturday.
In order to stop the fluid drips, I got these:
Amazon.com: OTC 4506 Fuel Line Clamp Set - 2 Piece: Automotive
As well as put a baggie under the brake fluid reservoir cap. Worked great until I had to remove the rubber lines. For that I had my gf step on the peddle which stops fluid from dripping but you still loose some.
Saturday:
I got wire brushes for my drill from Harbor Freight and spent most of of the day cleaning the calipers. What a PITA! They had the majority of rust removed but there were some places that were impossible to reach even with my dremmel. Where I could I used my bench grinder with the wire wheel on. I figure it should be ok as most of the vids I saw online people used a hand held wire brush for 5 minutes.
At about 8 pm I was ready to paint. I set them up in my basement verified at 66 degrees. The G2 paint itself sucks to work with. It is runny and doesn't stick well at all. The first two coats were about 30 minutes apart and it was still tacky. If I brushed too much the first coat would come off. I sat a fan in front of them for an hour and did a third coat on the parts that show. Glad I did as the back part still had the caliper surface bleeding through on sections.
I also was able to find the right lube - AGS BK4 Brake Lubricant. This is recommended for all surfaces and specifically the slider pins. The black stuff gums them up and could be the reason for my uneven pad wear.
I also found that you are not supposed to grease shimmed pads (my PS's have the rubber back so I didn't). I did gently grease where the pads ears sit in the carrier.
Sunday:
I just had enough time to install the brakes and calipers.
Here are the picks of my old crappy R1's after 40K - the rear ones are cracked too!
Here are the new power stops with the G2 painted calipers
Pretty happy with how they turned out.
Monday:
This was supposed to be an easy day - just install the stainless steel lines...boy was I wrong.
OMG the stainless steel lines were such a PITA it wasn't funny. They are not the same size as the OEM (slightly longer) but they were either touching the tire when turned one way or pulling too much when turned the other.
I then realized that they behave differently when the wheels are on the ground so I had to put the wheels on, lower it, then try. That went through about 4 iterations of disconnecting the lines and repositioning - blowing royally as it got to 10 PM by the time I finished.
I then had to re-bleed the fronts after it was all together (jacking the truck up again, removing the tires, then putting it together. What annoyed me is that the replacement lines (Goodridge) did not have the little "hook" on the banjo bolt that goes into the caliper to make it idiot proof like the OEM Armada lines. I was forced to loosen the banjo bolt with the copper washers everytime I repositioned them. I know you are not supposed to reuse them, but none of the auto stores in my area had them. Since it was only 13 ft/lbs and I did not actually drive at all I'm hoping it will be ok. No leaks at all for now.
The peddle is much firmer and my truck stops like never before though so all in all I'm happy.
I am getting a "tick-tick-tick" when applying the brakes that seems to be lessening as I drive. It almost sounds like the slots running past the pads. No idea what that is about but PowerStop said it could be faulty pads. I'll live with it an hopefully it will go away. Anyone here getting that? A couple guys on TT said they got the same but my R1's and OEM M3 brakes never made that noise. It almost sounds like a baseball card in your bicycle spokes but not as loud.
Anyway, thanks for the assistance guys!