I remembered that I had to thump the callipers with my rubber mallet to remove them and I realised pretty soon that it was going to be really difficult to get the bolt holes lined up just by thumping my shiny callipers back into place. I clamped the calliper into the vice and gradually filed each side of the top lug that was the cause of the tightness. It was slow going but eventually with a bit of cooper grease on the each side of the lug, I got the bottom bolt located and with a minimum of tapping I thought the top bolt was correctly located. Both bolts tightened, but unfortunately the top one when fully home just kept on turning round. When I removed it the thread was completely buggered.
I found a new correct sized, 7/16 UNF bolt in my bolt box, but not unexpectedly, with the calliper removed, it would only screw in about two turns. I would need to order a 7/16 tap and tap the thread clean before I could progress, but before I finished for the morning, I applied the angle grinder to the lug until the it would slip snugly into place allowing easy adjustment to ensure the bolt holes lined up.
The same day the following week I was back in the garage armed with my new tap and it only took a few moments to clean the thread and my new bolt firmly screwed fully home. Above photo shows the tap passing through the unthreaded lug and into the damaged thread in the other lug on the far side of the gap. The calliper slipped into place and I thankfully tightened both bolts up nice and tight, I fitted the new stainless flexible hose and turned my attention to the other side.
This calliper was also a tight fit. I didn't waste any time I took the angle grinder to it and very quickly it slipped into place and bolted up with out a problem. Over two hours to fit the first one and only about 30 minutes to do the second, but got there in the end.
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