Brian,
You obviously know what your doing  - a great job as well.
It's common practice to superglue the corners on the rotor seals,

someone

did suggest a special one but I can't remember.
However they should easily slide in the slot - did you clean the slot
thoroughly and test slide them before assembly.
Perhaps one of the corners wasn't exactly flush when you glued it on -

it's

a bugger of a job, especially when your getting old and blind like me.

BTW I wouldn't be hitting them with anything hard.
George (down under)

"Brian D. Cain" wrote:

Hey George, thanks for the compliment.  On the apex seal springs, I usually
don't
"dink" them very hard if they're showing some sort of resistance to being
slid in.  I
normally apply petroleum jelly to the seal and springs prior to insertion to
help them
slide in more easily and prevent just that sort of thing you've mentioned.
I'm not
hitting the seal springs very hard; just lightly tapping them with a pair of
needle nose
pliars (I keep those handy for removing apex seal springs if I have to).

As far as cleaning the slots, most definitely.  I don't know if you recall
off the top of
your head, but about a month to 6 weeks ago I posted a link to pictures of a
pair
of rotors that I had cleaned with some Zep Industrial strength stuff I
purchased
at Home Depot (local chain of giant home repair hardware stores here in the
states)
that I was raving about.  Those are the same rotors.  You're "right on" when
you
mention apex seal groove cleaning -> that's typically been the bane of most
problems
when assembling rotors.  The edges, for about half an inch or so, near the
corner seal
grooves, usually have the most carbon-like crud on them.  It'll definitely
hinder
apex seal insertion, but in this case I don't believe that's it.  I think
they were just being
stubborne. :)

On the super glue, it's been a fairly common practice of mine to keep a few
tubes handy.
We didn't have any at our disposal the night before last because we've just
moved
into a new shop space and didn't have all of our goods and resources moved
over yet.
But, it's definitely something I keep handy on about half of the occasions I
have to glue
the apex seals together for assembly.  You're dead right about it being a
pain in the rear;
you have to glue the corner piece on exactly right or it won't insert in the
seal groove...
been there, done that, got the t-shirt.  :)

B

 
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