Rule number 1 when rebuilding LR calipers,
DO NOT split the caliper body!!!!!!!!!!!!!
The spacer kits for converting solid discs to vented come with caliper spacers and seals, (Maybe give Graeme Cooper a call as they supply the kits from memory...) but as far as I know they aren't a widely available item.
The instuctions are quite clear even in the haynes manuals, DO NOT split the caliper, just use GENTLE compressed air to remove pistons.
Oh, And Simon, It is not the Defender that is cursed....I would be talking to experienced LR suppliers and repairers in future to avoid this sort of disaster again, especially with safety systems, IE brakes.
JC


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