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Should be about right, you want the gap for complete penetration into the sleeve at the right power setting for joining the two outer tubes. Otherwise you have to run far too hot and end up with a big slug of material on the outside.
A 0.625 going to each rear caliper individually is the issue, they'll be much too large with the tiny calipers on the rear.
I use that size master cylinder on each rear wheel for the handbrake with Wilwood 4-pots and 320mm discs....
Edit - don't know if the Clio's have the common 30mm piston...
It's surprisingly common, if I'd got paid for everyone I'd pointed out that was plumbed in before a prop valve or the wrong way around I wouldn't need to work again :D
The other fun one is people with bias bars adjusted 50:50 as they came from the manufacturer and then the prop valve cranked...
Ouch, yes, don't use 7075 where crevice corrosion is likely! At least anodise it...
6082 is far better suited for long term use where a couple of grams don't matter (and a caliper bracket is mainly about stiffness rather than strength anyway)
I had a set of the intercomps and they were faultless, very well machined for heights being matched too so they were usable on very stiff cars like formula single seaters with very low ride heights.
I looked at the str's because I want another set but I wasn't impressed enough to go for them, I...
Ouch, usually happens when it's not torqued enough so the shock goes through the front jaw instead of the rear.
Wooden bench doesn't help though, put a steel plate over the edge of the bench and then bolt down through it to support the throat.
If you run without it the alternator will spike when you turn the car off, and if you're lucky do nothing bar spark across the contacts. If unlucky kill the regulator in the alternator. If really unlucky it'll fry the ecu or whatever is the weakest like.
You might be able to grab one from RS...
As above, although the BMW manual box oil is usually okay - in fact one of the BMW oils is what I use for better shifts in some Peugeot and Renault boxes that are a bit sensitive to oils and have brass/bronze synchro's
Yeah, those cheap cats are shoddy as hell unless you get them red hot - they tend to have very little platinium, etc, compared to a proper one - what I've found helps if you have to use one is to wrap the cat and the pipe in front of it with a couple of layers of exhaust wrap - they light off a...
That dog was a f**king tool magnet, used to steal anything shiny and put it in a pile outside, like a magpie :D
Put a spanner or socket down for more than 3 seconds and it'd disappear into the distance.