Ok, did a search, figured I'd find info there, what I found was about 100 post's on converting the drum brake fronts to disk, or the conversation turned into " why not use a disk brake explorer rear axle, its cheap and easy".
What I'm trying to do is convert a waggy rear axle to disk brakes, build a kit that excepts both 6 and 5 on 5.5 rotors, and not full floater yet. This is going under our project/demo samurai, I've narrowed the rear end, and I'm switching to big 5 pattern. Basis is a 77 Waggy Dana 44.
I know that there are companies that build a dana 44 rear disk conversion, but its seems strange for a manufacturing company to "buy" something that we should build anyway.
So, what is the scoop? I've got chevy calipers, both a ford and chevy rotor. Is there anything I sould watch for at this point? Are there different Dana 44 axle flange's besides the 4 holes, mostly round with a notch for the wheel cylinder style I have?
So, any info would be great, and if someone out there has done this swap, and has abraket design they would like to share, I'd be sure and reimburse you with some braket sets when we build them.

Sounds like you're trying to produce a "bolt-on" type conversion? I've only worked with waggy D44's so far and they all had the same axle flanges that you are describing. I did a "weld-on" conversion for my 9" and used backing plates that are available from Rock Equipment. You could pm Tonyk and see if he could send you somepics maybe.

Can't offer you pics as the truck is since destroyed and gone........but a friend of mine and I did a Waggo rear Disk once and we built a caliper bracket out of plate that bolted to the backside of the Dana 44's axle flange and used a Jeep cj front rotor...chevy caliper... Worked for years tell the thing was endoed 9 times and scrapped.

NoRM
never of much help as a habit

Originally posted by Wilson
Sounds like you're trying to produce a "bolt-on" type conversion? I've only worked with waggy D44's so far and they all had the same axle flanges that you are describing. I did a "weld-on" conversion for my 9" and used backing plates that are available from Rock Equipment. You could pm Tonyk and see if he could send you somepics maybe.


Yep, bolt on is the only way to go as far as the general public is concerned. I have the plates you are speaking of, the weld on ones, we get them in bulk for local stock car guys, there about $6 ea and a good starting point. I want to use large chevy calipers though, so I can match the front and rear and carry one spare. I don't know why one would ever need a spare, but why not make it possible.

Originally posted by SkyMfg



I want to use large chevy calipers though, so I can match the front and rear and carry one spare. I don't know why one would ever need a spare, but why not make it possible.

Wouldn't ya need two...Left n Right ;-)

NoRM

You might want to try Caddilac rear callipers so you can have an E-brake. I think the are on the Eldarodo in the 70's, can't remember.

I used large GM calipers (same as my front), and rear disks form a Yukon (6 lug though) on my waggy rear.

Used weld on brackets from AA.

Only issue I have is the Yukon rotors I bought have bigger stud holes then needed, but the rotor stays centered on the flange when the wheel is bolted on so its a non- issue really.

Found out later that LIGHT DUTY GM 1500 rotors (rears pretty sure) would have fit perfectly on the 44 rear axle.

As far as large 5 lug, what I would do is go to the parts store, and start looking for rear rotors from years with that bolt pattern that would work, as far as fitting the axle flange.(were there any?i dont know)

I'm guessing you are redrilling the waggy shafts for 5 lug or making custom shafts?

Why 5 lug?

easier to convert fronts to any other pattern, than it is to do the rear IMO.

Also I plan on converting to a ebrake capable caliper later...might as well do that yourself as carrying spare calipers is waaay overkill IMO. (Unless you are going to be away form civilization for a long time )
MJ:)