I have no prior experience with car brake assemblies, so whilst the build manual showed quite clearly how the major components go together, there were two areas that I needed to figure out. Forgive me if this is a little basic!
First, the DeDion Ear was attached to the DeDion Tube after a smear of silicon sealant had been applied to protect the tube from water ingress. The Hub was then slid over the Drive Shaft with the aid of a little Anti-Fretting compound, and then bolted on to the DeDion Ear. The Brake Disc can then be slid onto the splined shaft, again with some Anti-Fretting compound.
Drive Shaft - Adding DeDeon Ear - Adding the Brake Disc
Then I needed to understand the Carrier and Calliper system. The first issue was how the Carrier (the cradle that holds the brake pads) connects with the Calliper. At the top of the Carrier, there were two black grommets that contained only grease. A separate bag contained a set of four black anodised pins, with hex heads but with a thread cut into the head. The black pins slide into the grommets such that the neck of the grommet can be located into a groove in the hex head. This pin can then slide in and out of the Carrier. The Carrier is then bolted onto the DeDion Ear and the brake pads are slotted into position either side of the Brake Disc. They must sit flush against the Brake Disc.
Now the Calliper, fitted with the Anti-Rattle Spring, is gently slid down over the top of the Brake Pads - the two black pins on the Carrier need to be pressed in to allow the Calliper to drop down into position.
Now the second issue - the Calliper would not fit over the Brake Pads. There just wasn't sufficient room between the casting and what I recognised as the piston. I used a Calliper Rewind Tool to get the piston as far back into the housing as possible, but it was still proud of the gasket by a few millimetres. On my second attempt to reassemble I realised there was a pip on the lower edge of the back side of the Brake Pad which needs to be seated in recess in the piston. The Calliper Rewind Tool was used to realign the piston and then the Calliper assembled correctly onto the Carrier. Two bolts pass through the inside of the Calliper and screw into the threaded holes in the black pins. It then becomes obvious that, as the piston is pressed into the inside Brake Pad, the Calliper slides on the black pins so that equal pressure is applied to the outside Brake Pad. As the foot brake is pressed the Calliper self-centres and the Brake Disc has equal pressure applied to the inside and outside surfaces - in theory!
Finally the Ant-Roll Bar was connected via the link arm to the bracket mounted on the rear of the DeDion Ear. Take care with this bracket - I discovered, to my cost, that the brackets are handed.