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Discussion Starter #1 (Edited)
5x4.5 Dana 60 Build

Plans:
- New brackets (Blue Torch Fab)
- 4-Link (Thorbeck Brothers)
- Truss/Diff System (Blue Torch Fab) BTF03056
- Disc Bracket (Blue Torch Fab) BTF11023
- Brake Rotor (Wilwood)
- Brake Caliper (Wilwood)
- Brake lines/fittings(Undecided)
- New Bearings/Seals (Spicer)
- Coilovers (Ballistic)
- Rear Sway Bar (Undecided)


Current:
- TJ brackets (designed for modified uppers)
- 4:88 Richmond Gears (RPD60488)
- Tru Track
- Strange Engineering 30 spline axle shafts (P3502)
- Shortened to 59" WMS



This is what I was given to work with:












I have not been able to find much 'number wise' on this axle...all the tube BOM numbers are no where to be found. The only markings on the whole axle are the 60 on the lower right of the pumpkin, and this C-30255 on the upper right.


Brakes
Here's my big mess...since there are no numbers to be found, all I have been able to do is go off of dimensions and forum information (this is my first axle swap/build). 5x4.5 patterns were only found in 60s-70s Mopar drag axles, after alot of research I have concluded that mine is NOT from a mopar muscle car. There are no pinion snubbers, nor any signs of holes where one could have been.

Strange Engineering is a company that deals primarily with drag applications, old mopars/dana 60's specifically (I learned that my shafts came from them). Obviously a previous owner shortened the tubes himself and ordered a set of shafts and the detroit from them... Excluding this, the whole axle has been modified in a very "low budget" manner, not quite worthy of my full trust(especially the welds!). SO if for some reason you want to 5x4.5 on your Dana 60, they sell 35 spline shafts that will fit a narrowed axle.

I have been in contact with Great Lakes Off Road, Exteme Axle Sales, and a few companies locally trying to figure out what I need. I wanted to throw out there what a good job both of those companys do. I never would have known to look at old Mopars without Shawn's input. Doug at Extreme Axles has gone out of his way to assist me brake wise given the limited knowledge I have. Hopefully I can put an order in soon!









You may notice that there are already disc brakes on here. Why do I need new ones? The brackets are poorly mounted, the rotor looks to be redilled from 5x5.5 to 5x4.5 in someones garage...it doesn't sit just right. The calipers are rusty on the inside(Being a used axle I would have bought new calipers/pads reguardless). The brake lines have been bent by hand...FULL of kinks, and I would prefer SS lines over the rubber hoses.
 

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Discussion Starter #2 (Edited)
(brakes continued)


We thought this was the teraflex rotor and would be easily swapped....wrong. (rotor depth 2 1/8")


Calipers from a mid 80's Monte Carlo from my understanding.




I finally got to pulling the shaft out so I could better see what type of flange was hiding under there, looks like a Big Ford(Old Style). While doing this I was able to find the culprit of a grease leak...guess im getting new wheel bearings too, huh?




you can see here(right behind the zerk fitting), one of the previous owners welded on all kinds of brackets. This one in particular prevents 2 of the 3 bolts holding the disc brake bracket from being removed.



 

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that looks like barrels-o-fun! I would cut all that brake stuff off and start over. I have a file for a d60 weld on bracket you could have jeff or someone cut out. I may be able to get it done at my new workplace since they have 3 machines. I think btf has a list of ford brake rotors and calipers that work with a 60 instead of using swiss cheese and chevy junk.

You might check out moser engineering if you plan on shipping any of it to get worked on. They're probably closer and their turn around time was fast when jason had some axles shortened and splined.

And if the cat that built it did it with his eyes closed one night while he was drunk, it might not be straight.....hopefully that's not why he sold it.
 

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if your interested in running our parts I can work a package deal for the article with a truss/cover and all the tabs needed for the four link and brake brackets with the parts list of what you would need to do everything. pm me if your interested.
 

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Discussion Starter #8 (Edited)
Had some time this evening to cut a few brackets off.





I got to looking at the bottem of the axle, and clearly there are ground down remains of what seems to be a lower truss?(probably some drag term i am not familiar with). The plot thickens...


Ended up cutting the bolts off the disc bracket




3/4" spacers



1/8" spacer
 

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Discussion Starter #9
Gave James at Blue Torch Fab a call today. He knew exactly what I needed and was able to square away my disc bracket issue! I'll be running redrilled brake rotors from a '73-'87 GM 3/4 ton front axle and calipers from a '73-'87 1/2 ton front axle. I'll order those up after I get the bracket mocked up to double check everything.
I'll be using BTF's Dana 60 Rear Truss System and Lower Coil Over Bracket System. Again, James was extreamly knowledgable about 4 links so he got all my bases covered as far as bracketry goes.
I'll be gone whitewater rafting this weekend...:D so hopefully next week I can find some time to get all the current brackets off.
 

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Discussion Starter #10 (Edited)
Parts came in from Blue Torch:



NICE welds!




THICK!

One of the pieces must've missed the box, I got ahold of James, and he OVERNIGHTED it. Thats customer service.

picked up some electrodes from evansville welding supply today, looks like the rest of the old brackets will come off friday and the truss will go on.
 

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Discussion Starter #13
UPDATE: axle dosent have enough flange offset (the shaft face isnt far enough away from the flange) so there isnt room to put the emergency brake part of the kit....which is what holds everyhting together.
I traced a new braket using part of the dana 60 section off of the Blue Torch 3/4 ton bracket, and the 1/2 ton pattern off the Wilwood kit so that I should be able to run these parts minus the parking brake. I'm going to email Carshopinc.com to see if I need to return the whole kit and rebuy the same rotors/calipers or if I can just ship back the parking brake piece.

Anyway, I was unable to find a 1/2 ton Dana 60 bracket anywhere online so thats why I had to make one (plus I KNOW it'll fit now).

:)hot: it penetrated REAL well when I tacked it up)

Lemme know if anyone wants this bracket, im gonna file this piece of cardboard away.
 

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Discussion Starter #16
Kind of been a slow streak, the brakes kit is still in the mail..should get back to carshopinc on friday. I'm supposed to get ahold of Wilwood once i get refunded to talk with them about my application and what they have that will work. If WORSE comes to worse and I get into a time crunch, I talked to a guy at advance auto parts on monday and he said he'll go through and find what my old rotor came off of.

I went in to order a set of the new Goodyear Kevlar's since goodyear has the $100 rebate for this month...of course they're on backorder:mad3:
Should have those on within a week or two.

Emailed Suicidedoors.com (a minitruck company) that's 30mins north of me about building my links...wait'n on a reply still.

Ive been watching the pbb for some 12-14" coilovers....once i snag a deal things should start happening alot faster.
 

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Hey man, I am trying to run this wilwood set up on a dana 60. Are you running semifloat?

there are 2 different offsets on the ebrake disc kits, 2.36" and 2.5"

what offset were you working with? it seems like a fullfloat set up would have plenty of offset if not too much.

any more info on this?
 

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Discussion Starter #18
Hey man, I am trying to run this wilwood set up on a dana 60. Are you running semifloat?

there are 2 different offsets on the ebrake disc kits, 2.36" and 2.5"

what offset were you working with? it seems like a fullfloat set up would have plenty of offset if not too much.

any more info on this?

Yes, my axle is semifloat, and I actually ended up having to return this kit due to the offset issue. I just got refunded last friday so I have not made any progess over the last month or so because that $600 had not been recouped yet. Carshopinc.com was very difficult to work with...
I called up Wilwood to talk to an engineer about finding a soultion that might work..."uh sorry, we dont make a kit for that...click"

here is where my shaft would have to be in order for it to fit correctly:

clearly, that gap is far too much to try and compensate for!

here is a picture of the emergency brake setup incase anyone is curious:


and the caliper resting on the rotor for a mock up:


What I ended up doing was walking into Advance Auto Parts, shaft in hand:grinpimp:, and standing there while we tried on every rotor I could think of! The colsest one we found was from a 97 Ford Explorer. The lug holes were a hair small and the center hole was about 1/4" too small. I bought a grinder bit(looks like what you'd stick in a dremmel...but about 1" wide") and did some circle's in the drill press; also bought a 3" sandpaper flap wheel and did the same. Drilled the holes to 5/8" and stuck em on...nice and snug:smokin:

(pic was taken while I was in the middle of doing it...not snug in this pic)
 

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aw man sorry to hear that! I have been on and off the phone with Wilwood the past few days trying to figure out what kit i need. So far i havent gotten the "click".

If you measure from the outside face of the axle tube flange to the outer face of the axle shaft flange (wms), you will then have the correct numbers as far as offset for the brakes. Wilwood has several rotors that can be used , and at your bolt patter there is far more selection than at my 6 by 5.5. I know you already returned the kit, but this setup would be very slick, and all you need is the correct offset rotor.





Yes, my axle is semifloat, and I actually ended up having to return this kit due to the offset issue. I just got refunded last friday so I have not made any progess over the last month or so because that $600 had not been recouped yet. Carshopinc.com was very difficult to work with...
I called up Wilwood to talk to an engineer about finding a soultion that might work..."uh sorry, we dont make a kit for that...click"

here is where my shaft would have to be in order for it to fit correctly:

clearly, that gap is far too much to try and compensate for!

here is a picture of the emergency brake setup incase anyone is curious:


and the caliper resting on the rotor for a mock up:


What I ended up doing was walking into Advance Auto Parts, shaft in hand:grinpimp:, and standing there while we tried on every rotor I could think of! The colsest one we found was from a 97 Ford Explorer. The lug holes were a hair small and the center hole was about 1/4" too small. I bought a grinder bit(looks like what you'd stick in a dremmel...but about 1" wide") and did some circle's in the drill press; also bought a 3" sandpaper flap wheel and did the same. Drilled the holes to 5/8" and stuck em on...nice and snug:smokin:

(pic was taken while I was in the middle of doing it...not snug in this pic)
 

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Discussion Starter #20 (Edited)
Yea...I wish it would have worked:(

I'm going to look at some 1985 Cadillac Eldorado calipers that have the ebrake built in...


hopefully I can make those work with the Explorer rotors. If not I either need a drive shaft style ebrake:


or just put it in gear whenever I park:mad3:
 
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