13.8" Rear Disc Upgrade in the works

[modular93fox]

Heres some photos of the progress...
Made some decent headway on the rear brakes this past sturday. Finaly got the design down for the brackets.. going to have them cut out for me hopefully this week.. heres a few pictures so far...




rotated so you could see the 2 different brackets. There will have to be a spacer between the 2, Im not sure if they can bend the metal at such angles to make it work as one piece. This is just for starters, hopefully this works out first try.

clint

[modular93fox]

meh, with a cruise/meet next Saturday I figured I should have atleast one mounted and ready for show. I finished one set of brackets using some 1/8 stainless steel... its what I had laying around. Its not funtional by any means, just wanted to check the autocad drawing to ensure its going to be correct. After one little tweak it was spot on. Heres the rotor/caliper installed (Just like a OE Dodge 1500..)...  oh yeah, I also had to replace the stock wheel studs with something a tad bit longer... no biggie..



muhaha cant wait to get the 3/8 lazer cut brackets from the shop...
clint

[modular93fox]

ah, today was a good day.. not because of work, but becuase the mail man an ups droped off both of my packages today:)



Got the spacer I needed, and the other set of brackets for the other side. Also got the hoses for the conversion, right at 30 bucks a hose with banjo bolt, crush washers and mounting bracket, and clip!
Gotta work Saturday, so Sunday I should have everything mounted and working!
clint

I whipped up a 3d design of the brackets "assembled" on a axle with e-brake adapter plate... havent got these laser cut yet, but hopefully i will make a prototype of the "main" bracket to test fit soon.

[inovermyhead]

How's the progress? 

[modular93fox]

Ive got everything bolted up, I just need to cut, bend and flare the 2 3/16 hardlines... ran out of daylight yesterday, and today was a waste... made the trip to the garage and didnt change clothes before I left... idiot.. oh well, Ive got everything in the truck to wrap it up after work tomoarrow..
clint

[treestandjunkie]

What does this swap cost to do start to finish??

[modular93fox]

total cost could be roughed out at:
Your cost on new or used rotors and calipers, I got a steal of a deal, 100 bucks (plus ebrake plate with hardware)
10 x Dorman 610-298 wheel studs - RockAuto.com price $23.79/box 10
Felpro Rear End gasket # RDS550281 (10 bolt) $2.51
17/32" drill bit Item # 1F549 from Granger $25.10 (a tad bigger than 1/2...)
Braided brake hose - I chose Kore3 brake hoses, $70.00 shipped for 2 14" hoses, banjo, crush washers AND mounting hardware. Hose assembly consists of one end being a 10mm banjo and the other a 3/8-24 IF (inverted flare) x 14" long. Other places sells the hoses, but for the price plus mounting tab... Kore3's price and service is awesome!
60" of 3/16 hardline - 7.00 + 2 additional brass "ends" @ $1.50each. 60" is a little more than enough to do the job. The additonal "ends" will allow you to make the passenger side hardline with the unused portion of the original 60 piece. These will go from the factory drop down hose to the aftermarket braided hose.
The brackets, bolts, nuts, and washers will probally be in the neighbor hood of 125. When I took a quick measurement of the spacer I needed, for some reason it was perfect on one side, or so it seemed perfect, it wasnt thick enough to make the caliper centered over the rotor. No biggie, could be remidied with shims (cheaper option) or having a "spacer" cut out and then machined... I think that would make the end price unattractive, and shims would not affect performance at all either.

The non-ebrake design is finished and functional. I am pretty close to finishing a prototype ebrake bracket (like the one in the picture) it replaces the non ebrake type (which is pictured in the rendering) The non-ebrake bracket is the real photo.

Nothing for sale yet, I need to test it out and see how the brake bias is... see if the PV needs to be modified.
clint

[treestandjunkie]

Thanks for the detail!

[modular93fox]

update:
Finally finished the bending and flaring the hard line tubing. I gravity blead the system for a while then did the buddy system to ensure all the air is out of the rear circuit. Man what a difference going from front brakes only to 4 wheel brakes. B/C of the truck being my daily, I deemed it necessary to bypass the rear brakes untill I was ready to put the discs on.. plus it was more modivation to get done!
As of right now the truck stops great, it has always stoped great with stock disc/drums. I went to our state inspection brake testing area and did the 20mph/25ft and stops within the markers. Even though the front rotors are glazed, they have to be, the fronts will still lock up (start to screatch) when the pedal is suddenly mashed. Im sure that is normal. I just did my homework on piston area percentages.... a few websites show the stock D-52 caliper to be at 2.80square inch piston. Alldata doesnt show anything for the stock chevy caliper, but they do say the Dodge's rear caliper to be at 54mm/2.12". The goal is as close to 70% in the front and 30% in the rear as possible. IF 2.80" for the stock D-52 is correct, then the fronts currently have 56% and the rear has 44%. Im not sure if I want to gut the prop valve or not.... I dont know what the guts of it look like... I dont know if you can mod them besides gutting them and adding an adjustable prop valve. What do you guys think?
clint

[choptop]

I'd add an adjustable proportional valve, that way you can fine tune the braking system, Awesome work by the way.

[modular93fox]

Thanks,
I was thinking I might try and gut the prop valve and see how the truck feels.... but I dunno. I almost would want to have an adjustable prop valve just incase. I dont have one at the moment. I will give it a few more days and let the pads wear in and such.
clint

[modular93fox]

[Skunksmash]

Notice any increase in stopping power?

[modular93fox]

Hard to say since I ran the truck for a month and a half before getting all of the R&D done. I forgot to hook up HP tuners to the truck and see what the 60-0 is. I will do it 2-3 times to see how consistant it ise... I will make more of an effor to remember this saturday. I also might try gutting the prop valve and making a run (after the system is blead). See if the front tires lock up 1st or not.

[azfabguy]

what's up with your brackets?