D60 Front Brake Upgrade

[70custom20]

Any more progress?

[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!

[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.

[Last_Paladin]

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)

3. Put an H2 wheel on and measure that. Mine are almost a HALF inch thick at the flange.

[SADMAX]

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.

[mcmlxix]

Originally Posted by SADMAX

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.

If I need to upgrade the bracket material, there is an option. Solid Axle makes a new hub that has .33x further offset, so the brackets could be made out of 3/8" or probably 1/2". I just wasnt going to buy new hubs because mine were still usable. If I have issues down the road, I can always take it to the next level.

As far as using 5/16 plate, my though was there isn't really any lateral force on the bracket, only rotational.

The only other option woud be machining a bracket out of billet. It would be alot more expensive but you couldn't beat the cool factor....

[truckeez]

Originally Posted by SADMAX

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.

what size are the 2003 hd chevy rotors
I got some cool 16"s to run on my d60

Wish I could have run the 14" dodge rotors, cant have too much rotor.

[mcmlxix]

Nothing yet. Out of town till the end of the month ...
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[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...