Ken:
I never ran into the 2nd half corrosion problem. Then again, I've only done it twice, on steel parts. Is your caliper cast iron? That's probably more susceptible to flash corrosion.
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What do you use for the zinc bright dip? I haven't done that before. I yellow chromate everything.
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Initially I used muriatic or sulphuric acid at @ 3-5% solution. You can see the effect on these parts:
Spring plate and
U-Bolts
I'm now using nitric acid at @ .5-1%, and it's MUCH better. It will help some even w/yellow chromate, but not as much as with clear chromate. Problem is, nitric is difficult to come by, and expensive to mail order.
Sean