D60 Front Brake Upgrade

[68 TT]

Originally Posted by mcmlxix

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...

Sounds like you are making good progress.

I would have given them all the wheel studs and let them install the whole set. No big deal to put them all in if they are setting up the press to install one already.

[mcmlxix]

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....

[68 TT]

Originally Posted by mcmlxix

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....

Ouch, that will add up in a hurry.

Definitely worth ordering online to save nearly 50% on the cost if the shop can't do much better on the price than $5.99 each.

$3.10 is a pretty good price on a fastener that size. Hopefully they don't kill you with shipping & handling charges.

[70custom20]

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

[mcmlxix]

Originally Posted by 70custom20

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

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....

[plummen]

Originally Posted by mcmlxix

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....

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!

[68 TT]

Originally Posted by plummen

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!

x2

Plus I hate paying someone else to do a job I can do myself.

[mcmlxix]

Well I'm still waiting to get the brackets TIG welded... but I did get my 5/8 studs pressed in...

[mcmlxix]

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)

[68 TT]

Originally Posted by mcmlxix

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)

I would trim down the tops of the studs or get open end lug nuts.

The cut lug nuts will rust on the end you cut too.

[70custom20]

Any more progress?

[mcmlxix]

Nothing yet. Out of town till the end of the month ...
Posted via Mobile Device

[1malo68]

Just read through yor thread and as far as Hydroboost lines, Nevada House of Hose can make any hoses with any fittings you want so you don't have to use adapters. FWIW

[mcmlxix]

1malo68 ~ I know of House of Hose and was leaning towards them when I get to that point.... thanks


I ordered a new caliper piston from the dealer... $34... I had chipped the phenolic (plastic) original during disassembly for powder coat... I need it before I can assemble everything... Once assebled and squared, I can weld the other half of the bracket in place... then make the jig... note to self, get something to make jig out of...

Here is a powder coated caliper... they will only fit a 17" or larger rim ...



and the tig weld on the bracket....

[ghettoluxury]

looks killer

[70custom20]

Sending this thread back to the top.

[ryanroo]

in for updates

[mcmlxix]

I just got my 3/4 x 12 x 12 steel plate that I will use as a jig to weld the brackets. I will have it water jet to match the mounting holes so it can be bolted together with close tolerances. I hope to drop it off this Thursday, but I may have to go out of town.... I'll have some pics and update when the jig is ready...

[mcmlxix]

ok.. so here is the plate cut as the jig... hope to get it TIGed this weekend...



The problem with this is I won't be able to test the whole setup for a while. I still need crossover parts, 2wd box, brake parts etc. before I can swap axles under the truck... plus it will be my daily driver from December till March... so the earliest I can START the swap is mid March provided I have the funds...

[70custom20]

Rich, keep us updated with progress as it comes, good luck.

[kiszka6911]

Hi Rich,

I a new member and suscribed because of this thread! Two questions, Can you provide the actual Dodge P/N for the Caliper and Rotor. Its much easier to order them if you have p/n's. Secondly, will you provide the CAD data on your brackets as I would like to get a set made. I am converting a dual wheel 60 front to single wheel and this would be great to do all at once, Thanks! Also wanted to say I converted to hydroboost using the unit from a 1990 1 ton chevy c/k30, and used a master cylinder from a 1991 K30 with JB8 hydroboost option.

[Safarik5]

Ive been following this thread after looking for a dana 60 brake upgrade. I wanted to offer a suggestion that might help with the lug problems.
maybe not this company but another company that makes thinner adapters. it might solve the problem with the studs having to be so long.
http://adaptitusa.com/8x650to8x650wheeladapter.aspx

and heres one thats 1.5 inches.
http://billetwheeladapters.com/8-lug...1-5-thick.html

im sure someone makes a thinner one. that way you can use factory lugs incase of wanting to use the 09-11 chevy wheel covers.

here is the thinnest ive managed to find at 1.25 inches thats probly about as thin as they get. and as an added bonus the hummer h2 wheels sometimes need kicked out a bit anyhow netting you even more clearance on those calipers.
http://www.performancewheeladapters....x6.5-GM/Detail

[jbclassix]

subscribing..., scheming...

[mcmlxix]

So this weekend I finished rebuilding the second caliper. I also smoothed all the sharp edges on the caliper brackets. They will be sand blasted and powdercoated. I hope to drop them off this week with some other parts.... I received my NWF crossover kit...

[jbclassix]

nwf parts look great! Im gonna look into those!