D60 Front Brake Upgrade

[jjzepplin]

Good work sir! This should be a nice rig with some great functionality!

[DWL]

Here are some of my pics. of my calliper brackets i built for my dana 60 using same disks and callipers (2012 ram 3500) also used master from 2007 k3500 callipers are machined out of solid piece 14x14x2 A36 plate then case harden to approx. 56 rc 20-30 thou.deep my reasoning for using a36 was largely cost motivated and seeing that no where on bracket is less than .700 thick failure was not an issue i want to thank mcmlxix for all the useful info.

[mcmlxix]

Those came out awesome! I like them better then my multi piece design that requires welding...

[ryanroo]

those certainly are sweet! i pondered that same approach when i did mine, but i dont have that kind of skillz on the CNC

[jjzepplin]

You should reproduce and sell those here.
Dumb question-but you got the calipers and discs from a 2012 Ram-Why wouldn't the caliper brackets from the same truck not fit?
Different design on the Dana 60 years?

[70custom20]

It would be great to be able to buy an aftermarket brake kit like this. You can buy just about anything you want for older cars as far as upgraded disc brake kits go, something like this is long overdue for trucks.

[DWL]

Used later model ram disks and calipers because there 14.125 dia. with large dual piston calipers [more surface area,bigger dia.,more stopping power]noticed a big difference in stopping performance

[70custom20]

DWL, what kind/year truck did you do this work to? Also, how about the rear brakes, did you upgrade to a rear disc as well, or swap a newer disc brake rear diff into the truck? Thanks

[jjzepplin]

First things first- SORRY- WELCOME TO THE FORUM!!!!
Now-
Why wouldn't the caliper bracket interchange from the same Ram truck?

[mcmlxix]

Originally Posted by jjzepplin

You should reproduce and sell those here.
Dumb question-but you got the calipers and discs from a 2012 Ram-Why wouldn't the caliper brackets from the same truck not fit?
Different design on the Dana 60 years?

The truck the brakes came from has a unit bearing design and the steering knuckle has the caliper mounting points built into that, no external bracket.

[mcmlxix]

Originally Posted by 70custom20

It would be great to be able to buy an aftermarket brake kit like this. You can buy just about anything you want for older cars as far as upgraded disc brake kits go, something like this is long overdue for trucks.

It takes a lot to mass produce parts.... it would be simpler and less of an investment to sell the idea (and cad/cnc files) to a company that is in the business to produce a bracket. The best thing he could do is get a copyright patent, then sell the idea...

[whitedog76]

I would think mass producing would be a PIA. You'd have to have the parts tested by the NTSB and so on. Not to mention the liability factor. You'd need to be insured out the wazoo.

[ryanroo]

I agree that it would be a pain in the butt. if sold as an off road only type of modification, i think(i have no info to back this) that you could be a little less liable. I know MCMLXIX has been asked to reproduce his, i have been asked to reproduce mine. i am just a little skeptical, and don't care to look into it.

[DWL]

I agree with the mass producing would be a pia. I did this conversion only because of the challenge of doing it and the concept made sense to me and it works. Its guys like all of us that keep these forums going and enjoyable just thought I'd share what I did . Keep all the good ideas posted as we all benefit!!! CHEERS P.S. someone had asked me what truck it is Its a 99 k3500 crew cab short box,wristed radius arm front suspension rad flow coilovers,1997 5.9 cummins 12 valve ,nv 5600 ,np 205 ,11.5 AAM out of 2007 k3500 single rear wheel. Just started test driving it and knock on wood so far so good Cheers again.

[ryanroo]

Originally Posted by DWL

I agree with the mass producing would be a pia. I did this conversion only because of the challenge of doing it and the concept made sense to me and it works. Its guys like all of us that keep these forums going and enjoyable just thought I'd share what I did . Keep all the good ideas posted as we all benefit!!! CHEERS P.S. someone had asked me what truck it is Its a 99 k3500 crew cab short box,wristed radius arm front suspension rad flow coilovers,1997 5.9 cummins 12 valve ,nv 5600 ,np 205 ,11.5 AAM out of 2007 k3500 single rear wheel. Just started test driving it and knock on wood so far so good Cheers again.

thats quite the rig! you should do a build thread in the 4x4 area or the conversions area. id love to see more of your work!

[83GMCK2500]

Are those dimensions of stock the minimum it would take or can 14x14x2 be minimized? Do you have a model (cad/cam) of those or the g-code?

Those brackets are gorgeous, great job on designing a one-piece solution.

[83GMCK2500]

DWL, I am really interested in building a set of these myself but my Dana 60 is a couple hundred miles away and fully assembled yet. I am not in a position to disassemble and take all the necessary measurements, but I am in a position to put some material into a vertical milling center. I would like to upgrade to this disc-over-hub arrangement as well. I would really appreciate the dimensions and from there I could model it and code it. Also, what diameter of wheels are required to clear your setup?

[mckustomfab]

^^^^^ x2 ^^^^^

[70custom20]

From reading what Rich posted, a 17" wheel is the minimum diameter to clear the calipers. From the pics posted, the wheels barely clear the calipers.

[ryanroo]

i can back that up. i have to leave the calipers and abutments off to use my 16" roller in the garage.

[6600DURAMAX]

I would be in on prchaisng a set of these brackets!!!!

[70custom20]

Originally Posted by 6600DURAMAX

I would be in on prchaisng a set of these brackets!!!!

Definitely a market for these parts. I would think a vendor like ORD would be might be interested in purchasing the design and would be able to capitalize on it and sell plenty of the upgraded brake kits. A Dana 44 version would also probably do well. Just my opinion.

[70custom20]

A couple more questions for the guys who have made the brake swap, where are you buying the rotors/calipers/ master cylinder from, dealerships? Salvage yards? Or an auto parts store like NAPA? Also, what brake proportioning valve are you using?

[ryanroo]

i got calipers rotors and abutment brackets from one of the local JYs. Mostly for mock up.

i want to get the EBC rotors and pads when i put the axle together for real. at that point i will likey get fresh calipers as well. i have no idea how long these sat out in the yard before i got them. i will be plumbing a wilwood adjustable prop valve in junt in case it needs it. master is from a 95 K2500 and was chosen based on its bore and compatibility with my booster.

[mcmlxix]

I got my calipers from a JY and had them powder coated locally. Then I put new seals in myself. I am using stock rotors and calipers from a local parts store. I figured I'm already 3 steps ahead with the larger components and parts store quality will be fine. (I understand Ryan's EBC upgrade for the beast that he's building.) I am also upgrading to hydroboost and using a 2005 GMC unit but I did plumb in a Wilwood adjustable proportioning block. I am also running a disc brake rear from a 2004 GMC that has dual piston rear disc brakes.

All this is still untested at this time... I have given up with time estimates as my paint and body guy is taking longer then expected...