Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

I got the DS kingpin out. I was surprised how easy it was, very minimal effort. I was scared to death bc of all the craziness I have seen searching the web. I just hope the PS is just as easy!



I had to clearance the bracket and knuckle a bit but I got the front bracket on finally. Test fitted the brakes too. This is a good bracket but I feel like it could have been a bit better, it is hella beefy though.









My dually rotor should arrive today so hopefully I can get it out for a test fit for the rear.

Now I need to start rebuilding the front... So new u joints are on order for the half shafts. However, I need new king pins, bearings, seals the works... $$ Gotta start search for the best deal, also brass bushings or plastic?

[Wide Open]

Looking good!
Those rotors look like they belong there.
Have you decided which wheels you are going to run?

[NastyBuzzard]

I agree, they are so huge but don't look out of place at all with that giant axle.

I can't use oem wheel studs, they were too short even stock. I upgraded to 610-303 wheel studs which are longer and still 9/16-18 thread but require the hub to be drilled with a 21/32 bit. Both the drill bit and the studs are on order to arrive by Friday.

[Wide Open]

So it's possible this would work on a dually axle then? Change out the studs and bolt the extension back on?

You chose the slip on disc because it's readily available off the shelf as opposed to a custom or kit setup right?
Posted via Mobile Device

[NastyBuzzard]

Right, that's how I feel anyways. Change out studs and bolt it right back on. Yes, I chose those slip on bc it is so much easier to service brakes, readily available, relatively cheap, and also because it is a way larger and better braking setup than anything you can buy aftermarket really. I mean wildwood sells a $1400 brake upgrade but its just a 13" rotor and dual piston caliper, it is slip on rotors but you have to buy replacements from them.

Downside is only if you like 15" or 16" rims. I know this setup will clear 17s but I haven't tried 16s yet.

[Wide Open]

I like it and think I'll try this myself. Once you do all the trial and error of course

No 15" wheels for me but I'm wondering if I can space the wheel out just a bit more than stock to be able to run my factory 16" wheels for winter.

[NastyBuzzard]

Sounds like a plan. It would be that much better if it could work for a dually!

[Wide Open]

I just looked at my front axle again and it seems there will be some added complication on a dually setup. The hub extension is screwed in not bolted so the extension would have to be drilled out and bolted on.
Posted via Mobile Device

[NastyBuzzard]

Show me some pictures?

[83GMCK2500]

It's not so much as a hub extension as the entire hub itself. What you're seeing bolted on is the rotor to the hub itself. The GMT-400 - Present duallys use an extension that bolts on over the rotor and wheel bearing.

Dana 60 DRW front hub:


My '96:

[NastyBuzzard]

I can't see it working with that setup. The rotor wouldn't clear the first part with the studs.

Only option I see is to run my setup with wheel spacers but some people don't like using spacers. Even though that's what GMT400 and up do.

[83GMCK2500]

Could you not bolt your rotor to the backside of the hub as is done in the original setup?

Somewhere along the lines I think spacers have gotten a bad rep from people using aluminum or home brew or something otherwise equally scary. I've got steel spacers on the rear of my '96 (between the duals) that fit hub centric to the hub and provide a hub centric ring for my wheel to seat against. It couldn't be anymore factory-esque. No issues. I rotate tires-wheels regularly and I've yet to find a loose nut or a see any cracking or deformation anywhere. Plus, as you've pointed out, the factory uses a forged set up front on later trucks.

[Wide Open]

Yeah the IFS setup is different.

So maybe a slip on rotor will work?

[Wide Open]

Picture taken through the wheel so it isn't the greatest but I don't have time to pop the wheel off today.

[NastyBuzzard]

One thing I see is that the "front" of the hub pictured, where the bolts go through isn't a machined flat surface so isn't a good surface for the rotor to sit against. Plus like I said, I don't think the hole in the rotor, which is about 5" will clear over the surface to mount the wheel.

However, there may be ways to find a larger/better brake system to fit behind the hub or you could swap to SRW hubs and use spacers but I wouldn't buy cheap ones.

[Wide Open]

How do I get pictures to be embedded instead of stupid attachments?
Posted via Mobile Device

[NastyBuzzard]

I use photobucket. It is a website/app where you load in your pictures, then you select the pictures and it supplies an image link to copy/paste inside your text.

[Wide Open]

I think the rotor definitely has to go behind the hub, extension or whatever it's called like original.
The question is will the bracket for the caliper line up that way
Posted via Mobile Device

[Wide Open]

Yeah I'm familiar with Photobucket just don't really like it.
For whatever reason my picture is showing up now instead of just the attachment.

[Wide Open]

Originally Posted by 83GMCK2500

It's not so much as a hub extension as the entire hub itself. What you're seeing bolted on is the rotor to the hub itself. The GMT-400 - Present duallys use an extension that bolts on over the rotor and wheel bearing.

Dana 60 DRW front hub:

So what do those back bolts actually do? Just bolt the rotor on and the hub/extension is what holds the wheel on?
I've had several of the 96-99 trucks and I am familiar with those but now I have a new to me 86 that I'm just learning about.

[NastyBuzzard]

Yes, it appears those bolts attach the rotor to the hub as far as I can tell by google searching an image of the dana 60 DRW front axle.

In its current form the bracket would put the caliper too far forward for the rotor, however, that offset is capable of being changed. If I had a drw axle I would model it up but unfortunately, I don't. Still though, It is possible it could be made to work as long as there is room on the knuckle to move the mounting point of the caliper back. However, the bracket is already really close as is, so IDK for sure.

[83GMCK2500]

Originally Posted by Wide Open

So what do those back bolts actually do? Just bolt the rotor on and the hub/extension is what holds the wheel on?
I've had several of the 96-99 trucks and I am familiar with those but now I have a new to me 86 that I'm just learning about.

Yes, that is correct.

Originally Posted by NastyBuzzard

Yes, it appears those bolts attach the rotor to the hub as far as I can tell by google searching an image of the dana 60 DRW front axle.

In its current form the bracket would put the caliper too far forward for the rotor, however, that offset is capable of being changed. If I had a drw axle I would model it up but unfortunately, I don't. Still though, It is possible it could be made to work as long as there is room on the knuckle to move the mounting point of the caliper back. However, the bracket is already really close as is, so IDK for sure.

Does your dual piston caliper sit in the same location as the factory single? Better to ask, is the center of the disc portion in the same location as the original? It may be possible to find a rotor with the correct depth hat and of the larger diameter you're using to keep your caliper bracket as-is. I'm not following what you mean by the caliper too far forward for the rotor?

[NastyBuzzard]

I believe that it is farther forward than stock location but I will have to check for you.

[Wide Open]

Originally Posted by NastyBuzzard

I believe that it is farther forward than stock location but I will have to check for you.

By forward do you mean closer or farther from the knuckle?
Posted via Mobile Device

[NastyBuzzard]

Originally Posted by Wide Open

By forward do you mean closer or farther from the knuckle?
Posted via Mobile Device

I meant further away from the knuckle. However, I placed the original caliper bracket up next to the new one and they seem to be very close to the same spot! So that is some good news!

Other good news is the dually rotor worked! I can have slip on rear disc brakes!! Don't mind the location of the caliper, I didn't have it all completely together. Test fit.