Originally Posted by Maxxd07 (Post 4808939)

Wow that is some great work!

Originally Posted by mcmlxix (Post 4808999)

Thanks. The waterjet makes it look like I actually know what I'm doing...

Here is a link to the dorman catalog... http://www.dormanproducts.com/catalog/2006_hardware.htm

I'm going to need longer wheel studs... which seems to be more difficult then originally expected. The hole in the hub for the stud is larger then most of the options in 9/16-18 and if you upgrade to 5/8-?, they dont seem to offer a 60* lugnut for aluminum rims... just 90* seat for "other" rims ...

The factory studs are 2.5" and I was looking for 3.75" or greater....

Originally Posted by 68 TT (Post 4809506)

What knurl diameter is in the hub?

Originally Posted by mcmlxix (Post 4810295)

The stock knurl diameter is listed as .65 and I measured all of my studs that came out of the hub with a range of .642 to .648

The 14mm was a thought because my rear (the one I might sell, long story) has the 14mm - 1.5 but none of the dimensions work...

They make a longer stud in 9/16 but its only 3-9/32" and I wanted at least 3-3/4" ... also, the knurl is .677 so I would have to drill... (610-303 dorman)

I did find that Gorilla makes a lug nut for the 5/8 with the correct 60 degree seat so I think I'm going to upgrade to a 5/8 stud.. its knurl is .657 so I probably wont need to drill.... (610-418 dorman)

Originally Posted by mcmlxix (Post 4700895)

Not really.... I got a spare factory bracket two days ago and started to cut and modify. It looks like there are some interference issues. I had exchanged the Dodge rotor for a Chevy rotor because the offset was too deep to use with the factory bracket. I have since picked up another Dodge rotor so I have both to check fitment. I have also ordered a 2009 Dodge 2500/3500 caliper. The Chevy caliper does not fit the Dodge rotor because of overall diameter.... Right now I need some one to waterjet or CNC cut a 3/8" straight bracket...

Here is the factory bracket with one of the ears cut off...

http://i70.photobucket.com/albums/i9...ket_59955_.jpg

Here is the Chevy rotor and caliper bracket ....

http://i70.photobucket.com/albums/i9...ket_59956_.jpg

http://i70.photobucket.com/albums/i9...ket_59957_.jpg

I did pick up a Astro/Safari Hydroboost unit as well as one from a 2005 GMC 3500 truck. I am glad to report that they are interchangable between the two as far as mounting goes. One difference is the Astro has a single keyway where the newer unit has dual keyways. The Astro also has a smaller diameter hole for the master cylinder compared to the GMC 3500. The Astro HB shold support the late 70's Corvette MC for disc/disc brakes. I am using the 05 hydroboost w/ MC and have the Astro/Safari unit in the For Sale section. My goal was to establish if CaptainFab's brackets will work on the newer hydra boost and it does....

Here is a link to the CaptainFab bracket... CLICK HERE


here is a pic of the Astro/Safari hydroboost

http://i70.photobucket.com/albums/i9...ket_59406_.jpg

Originally Posted by plummen (Post 4819561)

if you still need the brackets made ive got a guy about an hour from here that has cnc plasma cutter im taking some parts to next week to have made

Originally Posted by mcmlxix (Post 4819891)

On Thursday I dropped off the brackets at the welder to TIG the spacers in place. Hope to pick them up next Thursday. Still need to grind the spindle flange to clear the caliper abutment. Got the RH caliper from the brown truck on Friday. I will probably disassemble and powder coat them red. The RH hub was dropped off to be machined and I left them with one 5/8 stud to test fit (press in.) I also ordered some lug nuts off eBay...

Originally Posted by mcmlxix (Post 4821088)

I only had one stud... Got it from the local parts store and it was $5.99.... I can get them on line for $3.10 each but I asked them to price out the rest of the studs from thier supplier.... I'll need 15 more... so its a decent chunk of change....

Originally Posted by 70custom20 (Post 4835341)

Everything is looking great! Getting closer to a complete setup every day.

Originally Posted by mcmlxix (Post 4835998)

Its all going too slow for me... I dropped the brackets off to get tig welded and then my guy had to go help in a pit crew for some offroad race truck event.... so that got pushed back a week... hopefully Thursday...

I just dont have the tools I need to do stuff myself... so I have to depend on others... wleding, machining, or even a simple press....

Originally Posted by plummen (Post 4836330)

Yeah thats why ive amassed so many tools and learned to be self sufficient over the years as much as possible,waiting sucks!
Well that and i tend to never be satisfied with the way most things turn out when other people do my work! :lol:

Originally Posted by mcmlxix (Post 4846059)

OK. I assembled the hub, rotor and H2 wheel... and my extra long lug nuts are too short...They bottom out the stud on the inside of the lug nut... I cut the top off of two and that works... So I have two options...

1. Cut the tops off all the lug nuts
2. Cut down the tips of the wheel studs. (not even into the threads)

http://i70.photobucket.com/albums/i9...3413351374.jpg

Originally Posted by mcmlxix (Post 4846059)

OK. I assembled the hub, rotor and H2 wheel... and my extra long lug nuts are too short...They bottom out the stud on the inside of the lug nut... I cut the top off of two and that works... So I have two options...

1. Cut the tops off all the lug nuts
2. Cut down the tips of the wheel studs. (not even into the threads)

http://i70.photobucket.com/albums/i9...3413351374.jpg

Originally Posted by SADMAX (Post 5269476)

Im building a D60 Axle almost from scratch as they dont produce what I am looking for. Like you, I don't like the brakes origionally used on the D60. So I like your thread and progress. My idea is similar to yours in that I was using the factory 2003 Chevy 2500HD brakes since they are already installed on my truck. Since reading this thread I liked the size difference of the Dodge rotor only for one reason. I installed a tone ring on my hubs similar to what Danatrac did. My Chevy rotors have more room than the D60 rotors but it was tight. The dodge Rotors will give plenty of room to mount the sensors. Anyway here is my thoughts/issues with the brackets. Im not sold on using 5/16 plate for the brackets. Even the 3/8 is somewhat iffy IMO. I havent ruled it out yet just a concern as Im driving this on the road as much as the dirt. Also I am having issues with the Lug bolts. I found a Dorman Bolt you may want to look into the 610-215. It looks good in that the rotor holes are very snug to the bolt. Probably the best we can find that is already produced. It may need a couple thousandths taken off the shoulder area but I will see. First I need a lug nut to ensure it will work in my wheel. Good luck with getting this finished.