I posted this up in another thread as it developed. But i think it needs its own thread for easy location in future.

Items used.

1. Disc Brake Conversion "Weps Style" with Chevy 3/4 ton rotors using original hubs with machining and new flanges.

2. Four Piston Brake Calipers from 68-82 Chevy Corvette.

3. 1/2" Thick Plate steel for Brace and mount.

This is my first one that is the prototype so there is definitely some more room to add some more meat to the brace around the caliper. My next set will have that filled in. The average depth of the brace is just shy of 1” with the thinnest sections around the caliper at 5/8” deep.

http://i141.photobucket.com/albums/r41/kabukirocks/S5001141.jpg

Some grinding to the calipers…more than what is needed.
http://i141.photobucket.com/albums/r41/kabukirocks/S5001135.jpg

Brace attached to the caliper. This is where you can see where the extra material will be added back in.
http://i141.photobucket.com/albums/r41/kabukirocks/S5001146.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5001147.jpg

Attached to the portal box...yes i know the portal box is broken. But check out that nice fit with the portal box. Nice work i must say so myself. :smokin:
http://i141.photobucket.com/albums/r41/kabukirocks/S5001150.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5001149.jpg

Calipers on rotors. Only .050 of pad not in contract with rotor at the very top. http://i141.photobucket.com/albums/r41/kabukirocks/S5001148.jpg

Looks awesome. just think how cool it would be if someone cast that entire piece out of STEEL.:smokin:
oh well, back to reality.......:shaking:

Looks awesome. just think how cool it would be if someone cast that entire piece out of STEEL.:smokin:
oh well, back to reality.......:shaking:



Well..... we know of a place where you can get that whole thing MACHINED out of a chunk of steel :)


.

Well..... we know of a place where you can get that whole thing MACHINED out of a chunk of steel :)


.

You can also get the whole box machined out of a chunk of aluminum if you wish. There is a company that does this.

But i think i'll try this first, at a cost of less than a $20 bill total, and a little bit of time.:smokin:

EDIT: apparently you know of said company :)

Well..... we know of a place where you can get that whole thing MACHINED out of a chunk of steel :)


.

That is WAAAAAY out of my budget:laughing:
The blank steel cut out is probably like 225$ BEFORE he even turns the machine on.:eek:
I realize what time and energy goes into the MSI's I am not ( and never have) knocked them or for him to step up to the plate for us 404 guys.

just that a cast steel piece would get closer to net shape, plus less machine time gives a lower overall cost.

I am dreaming anyways, nobody in american (foundries) wants to do shit anymore,:shaking: but that is another topic.

I realize what time and energy goes into the MSI's I am not ( and never have) knocked them or for him to step up to the plate for us 404 guys.




I just got my delivery from MSI today...... 24 Lbs (ea) of CNC'ed Porn!! :D

http://www.norcalbigdawgs.net/Gallery/albums/album75/DSC01587a.jpg

http://www.norcalbigdawgs.net/Gallery/albums/album75/DSC01588a.jpg


Really beautifully made.....I think I will just sit here and stare at them for the next few weeks.



.

Damn those are pretty!

If i have a failure I plan on going that route. But till then I'll see how much the braces box will take.

Whats yours going into tortilla?

I just got my delivery from MSI today...... 24 Lbs (ea) of CNC'ed Porn!! :D



I hate you.

















:flipoff2:
(SWEET)

When you get the braces perfected, what will they sell for?

When you get the braces perfected, what will they sell for?

I hadn't planned on selling them. But if some people want/need some i could probably burn out a sheet of them at a local laser shop.

I would- the whole thing is a good job overall:)
You may not get rich, but its' pocket money. Plus your tenacity has proven folks like me to be wrong!:laughing:

Thanks, They are pretty sweet.

I'll get some prices figured out. i needed to pick up another quarter sheet of 1/2" for some bender arms anyway.

Thanks, They are pretty sweet.

I'll get some prices figured out. i needed to pick up another quarter sheet of 1/2" for some bender arms anyway.

That would be so sweet if you could make your braces available. I'll keep watching...

That would be so sweet if you could make your braces available. I'll keep watching...

I second this!:grinpimp:

Ok ok. i'll make the last few design changes to fine tune it and get a quote out to one of the laser shops we deal with.

OK. I've got some other parts being lasered out now, and will be able to burn out these braces if anyone wants any.

PM me for Details.

Latest version with a little more meat.

http://i141.photobucket.com/albums/r41/kabukirocks/S5001248.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5001249.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5001250.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5001251.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5001252.jpg

very nice work i am inerested if you could send me the info on them to
doot4x4yahoo.com

thanks

BTW. This will probably be a one time thing. In about 2 weeks I will burn out all of the pieces that i recieve money for. I may run an extra set or two at that time, but its no likely. I don't plan on becoming a vendor and stocking any items for sale. I am just doing this to help out a few other pirate members that want to incorporate this idea.

Got my hubs back from buddy who Tig welded them for me. Assembled everything, and all works perfect.

It turns out i had the different castings for each of my axles. One had the extra reinforcements and the other didn't, so there were some minor differences in the fitment of the braces.

http://i141.photobucket.com/albums/r41/kabukirocks/S5000982.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5000983.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5000985.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5000984.jpg

Once the brace is installed it cuts down the space to install the bolts to hold it to the backing plate. You have two options at this point. Either run a shorter bolt...or drill out the threaded holes in the backing plate and run a bolt through from the backside and use a nut on the portal box side.




I ran studs in my brake caliper brackets.

I ran studs in my brake caliper brackets.

I wasn't refering to the caliper brackets but the bolts holding the portal box together. But yes, studs would work in that application as well. I'll update my post above.

Using studs would be the best option.

nothing really related here. Just mocking up my rear steering axle with some 44" racing slicks after putting the boxes on.

http://i141.photobucket.com/albums/r41/kabukirocks/S5000993.jpg

Hey Kabuki have any more parts left over or would you share your .dxf?

Hey Kabuki have any more parts left over or would you share your .dxf?

x2!!

Since there are two of you interested i could probably just burn out two more sets. I just picked up the first sets from the laser shop during lunch today and they will be going out in next couple days.

PM me if your interested.

kabuki

Hey Kabuki!

Does this rest on a lip on the portal box or do you need to mock it up for welding?

Hey Kabuki!

Does this rest on a lip on the portal box or do you need to mock it up for welding?

I would mock up to weld as its dependent on your rotor location. There is some flexibility as the 4 piston caliper floats on the rotor. I also used to washer as a spacer between brace and the caliper just to make sure i didn't weld the brace on to close to the rotor. If its a little to far away you can just use a spacer. But I wouldn't recommend putting it a large distance from the brace as you want the brace as far foreword on the box as possible.

I'll take a side shot of my box tonight to show where mine is mounted on the box tonight.

Damn...just realized my star expired.

http://i141.photobucket.com/albums/r41/kabukirocks/S5001073.jpg
http://i141.photobucket.com/albums/r41/kabukirocks/S5001075.jpg

hey kabuki, could you burn a set of those caliper brackets out for MOG newbie :-) PM me if you can

the portals are cast steel, is this correct? So MIG'ing them is not an option?

the portals are cast steel, is this correct? So MIG'ing them is not an option?

its weldable. take the box or the hub and hit it with the bench grinder, do the same with some mild steel and you will see the exact same color.

In this case you can MIG it.

ok sweet, cause if i had to TIG it i would have to do it at work and that probably wont fly with the owner.

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230011.jpg

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230012.jpg

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230013.jpg

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230015.jpg

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230016.jpg

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230017.jpg

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230018.jpg

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230019.jpg

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230020.jpg

http://i132.photobucket.com/albums/q2/PuckerFactor/Pucker%20Factor%20II%20-%20Blue%20Torch%20Fab/P7230022.jpg

I like your brake brackets! I suppose you set them up and then tacked them in?

lookin good. doesn't look like you lost to much meat at all going with that caliper.:smokin:

Looks good, what caliper is that?
(maybe I missed it reading back thru)

Looks good, what caliper is that?
(maybe I missed it reading back thru)

It's a Dodge 1 ton with one huge single piston. I got my mogs from Taradon and he fab'ed all the brackets.

As far as the lost meat, I had to grind off, I welded the horseshoes to my brake bracket which more than makes up just a little grinding.
I now feel more confident in beating the shit out of my mogs.
Thanks again Kabuki

I like your brake brackets! I suppose you set them up and then tacked them in?

Yea, I always tack things up first and double check everything for clearances. One thing I had to do was to get all-thread rod (M10x1.50) and nuts to bolt the bottom of the portal box together because the horseshoe brackets interfer with the stock bolts.

Yea, I always tack things up first and double check everything for clearances. One thing I had to do was to get all-thread rod (M10x1.50) and nuts to bolt the bottom of the portal box together because the horseshoe brackets interfer with the stock bolts.

yep. stock bolts won't work anymore with the shoes. got to set it up as studs just like you did.

wish I was making progress on my build...ugh. I'll be trying to tear them down the rest of the way tomorrow though :-)

I just bought a 55 mog and worried about the axle strength when going BIGGER ?! Should I worry about the front and rear? I'm interested in getting some of your braces when you burn some more off. How much do you need for a set? Thanks for the info.

Have you tested your brakes yet? What master cylinder did you end up using for this setup? I am using a ZJ master and am afraid its going to be too small. IIRC the four pistons were small and didnt need alot of volume to work.

Nice job!!:smokin:

I would mock up to weld as its dependent on your rotor location. There is some flexibility as the 4 piston caliper floats on the rotor. I also used to washer as a spacer between brace and the caliper just to make sure i didn't weld the brace on to close to the rotor. If its a little to far away you can just use a spacer. But I wouldn't recommend putting it a large distance from the brace as you want the brace as far foreword on the box as possible.

I'll take a side shot of my box tonight to show where mine is mounted on the box tonight.

Damn...just realized my star expired.

I am fixing to weld on my box braces and really don't want to put the box together just to mock up the location. Can anyone give me that dimension that the braces measure off of the face of the portal box? It looks like the front face of the braces just about lines up with the face of the cast piece that is used to pin the drum brake shoes.

Any help would be greatly appreciated.

I am fixing to weld on my box braces and really don't want to put the box together just to mock up the location. Can anyone give me that dimension that the braces measure off of the face of the portal box? It looks like the front face of the braces just about lines up with the face of the cast piece that is used to pin the drum brake shoes.

Any help would be greatly appreciated.

Did you do a disk brake conversion and using them as caliper mounts? Or are you just using them as braces?

If using them as caliper mounts mock up your brake setup with the mount attached to the caliper. that is where they go.

If using them just as a brace, simply make sure they don't interfere with anything else as the placement isn't that critical but i try and get them towards the front of the box.

Did you do a disk brake conversion and using them as caliper mounts? Or are you just using them as braces?

If using them as caliper mounts mock up your brake setup with the mount attached to the caliper. that is where they go.

If using them just as a brace, simply make sure they don't interfere with anything else as the placement isn't that critical but i try and get them towards the front of the box.

I am using your braces. I bought them from someone that got them from you. I am using the same 78 chevy rotors and corvette calipers. I understand how to mock them up. I just hate to put the portal box together and press the hub back on to mock it up and then have to take it all back apart to weld it up. I was hoping that there was a dimension that you could give that would tell me where to weld them.

I am using your braces. I bought them from someone that got them from you. I am using the same 78 chevy rotors and corvette calipers. I understand how to mock them up. I just hate to put the portal box together and press the hub back on to mock it up and then have to take it all back apart to weld it up. I was hoping that there was a dimension that you could give that would tell me where to weld them.

unfortunatly its dependant on where you placed the rotor when doing the disc brake conversion. You would only need to press up one box to get your dimension.

One advantage of using the corevette calipers is that they are floating so it doesn't have to be 'exact' and you can easily shim them with a washer if need to move them out.

If i were you i would just place the hub/rotor on top the box. This will be close and you know that it won't be able to mount any farther back than that. Put your caliper on and tack the brace in place there. You will likely end up putting a washer in later between brace and caliper to space if over, but shouldn't be any more than that.

Thats going to be really close to the final dimension right there. And like I said it won't be any further in than that.

Have you tested your brakes yet? What master cylinder did you end up using for this setup? I am using a ZJ master and am afraid its going to be too small. IIRC the four pistons were small and didnt need alot of volume to work.


Well, after 2 1/2 years I finally got it out of the garage and drove it around the block. :beer:

The brakes work ok in 2 hi. I have not gone over 15 mph yet. Still testing things. I have put the 4 sp. Atlas in 4 Lo and Low range. It won't even come close stopping the automatic in gear. I must shift to neutral to stop but I expected this after having a TJ with auto and atlas 4.3.

Only thing left with the build is the dash with 8 guages and 14 switches and a ton of wiring.

does it matter what year and model to pull the rotors off of when using the weps style brackets? Im trying to buy some from summit or anywhere online since I am stationed over in the uk right now.

does it matter what year and model to pull the rotors off of when using the weps style brackets? Im trying to buy some from summit or anywhere online since I am stationed over in the uk right now.

see below.

LOL. got to give you a hard time about this one. Found the answer....very first post of this thread.:flipoff2:


I posted this up in another thread as it developed. But i think it needs its own thread for easy location in future.

Items used.

1. Disc Brake Conversion "Weps Style" with Chevy 3/4 ton rotors using original hubs with machining and new flanges.

2. Four Piston Brake Calipers from 68-82 Chevy Corvette.

3. 1/2" Thick Plate steel for Brace and mount.

This is my first one that is the prototype so there is definitely some more room to add some more meat to the brace around the caliper. My next set will have that filled in. The average depth of the brace is just shy of 1” with the thinnest sections around the caliper at 5/8” deep.

ok guess i didnt word it right. What year and make 3/4 ton? Every site you goto ask for a year and make. I know to make sure it has the right bolt pattern, which is only on 3/4 and 1 ton trucks. Just dont want to order and get them and then they not fit the calipers. Takes long enough to get heavy stuff here as it is.
thanks for the quick help though. As soon as I get these my TJ will get the axle treament finally.

by the way - i did search, i think ive been through every mog build on this site about 4 times each, everyone always states something but never the full detail. and i figured id get flamed

just do a 78 chev 3/4 ton 4x4

Sweet! thanks mate! just ordered.

figured the new updates were worth a new thread.:grinpimp:

http://www.pirate4x4.com/forum/showthread.php?t=700796