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Old 04-07-2015, 11:02 AM   #911
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Well Howdy Folks --- Still wrangling with the front disk brakes. After scrounging all over the planet to assemble a set of new bearings & grease seals that are either no longer made or priced beyond reason, I was finally able to do a test fit to see if the wheels would clear the mongo Ford 350 brake calipers.

Of course not.

Problem being that when I started this brake swap way back when, I was still hoping to keep the original 20" wheels. They were changed to 19.5" rims when it was determined a new rear axle was the only way to reach anything close to highway speed. You wouldn't think a half-inch would make that much difference. It does. The brake kit was designed around the old style factory rims which, while only a smidgeon larger in diameter...are laid out entirely differently. The old rims go straight in along the outer surface and the new ones go in at an angle which creates the conflict.

Something had to give.

Since there are really few options, I checked with a trusted master mechanic friend about removing some metal from the calipers. He looked'em over and declared they were so overbuilt that grinding away along the trouble area should leave more than adequate metal. Being a bit shy about grinding away at something like a brake caliper, I took the conservative route. That means...grind a little...test the fit...grind a little...test the fit. It must have taken about twenty rounds of playing on-and-off with the 140 pound wheel before getting close. I won't have to go to the gym for a month.

After the first one was done, the second was relatively easy. Just match the first as close as possible. Thank God for seven-inch angle grinders and 36 grit flap wheels.

Anyhow, they both now fit inside the rims with just enough clearance to (hopefully) allow for any wheel flex (many thanks to Ol' Trunt for that heads up).

Here is what they look like now...



Ya...there is a fair amount of metal taken off but I did discover that this is actually a pretty common fix among racers and such, so let's hope for the best.

Oh...and speaking of "the best", below is what a brand new set of grease seals looks like. Or, at least what the package looked like...about 1952.


Always amazed at some of the NOS stuff that still shows up. The seals looked flawless...and yeah...I'm gonna keep the box.

Plenty more to do, so...

Onward!
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Old 04-07-2015, 11:35 AM   #912
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Not to worry Tango. The bus will stop even without the calipers. Just kidding, I can't imagine that that little bit of grinding would hurt anything. I'd be inclined to shock test the system a half dozen times somewhere flat and safe and then remove the calipers for visual inspection and perhaps a good magnafluxing looking for stress cracks and the like. When all that turns out good---well, it's like everything else we do on these old whoopties--Ya pays Ya money an Ya takes Ya chances! Jack
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Old 04-07-2015, 09:32 PM   #913
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[QUOTE=ol trunt;Ya pays Ya money an Ya takes Ya chances! [/QUOTE]

You got that right Jack! But you'd think that the MORE you spent...the BETTER your chances might be. If that was the case, you and I would be guaranteed some security. But somehow, it just doesn't seem to work that way does it?

Onward...into the fog!
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Old 04-10-2015, 05:44 PM   #914
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Finally...All four feet are back on the ground! --- After months of searching, scrounging, fabbing, patching and whittling metal, at least the front end now has disk brakes on freshly rebuilt spindles. The final fit...gave me fits. After getting all the brake parts modded and assembled, the new 19.5" rims were rubbing against the mongo calipers. I wound up removing quite a bit of metal but given how massive and overbuilt the Ford 350 calipers are, I am hoping they are still up to the task.


Down on all fours...er, make that sixes.



Couldn't resist throwing a little red paint on the caliper bodies.


The custom disk brake kit includes some serious hardware. It should be able to haul down just about any load at any speed.


Still have the rest of the brake system to put together (from scratch). Everything from the pedals to the master and hydroboost to all new lines.

Still more fun yet to come.

Onward!
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Old 04-10-2015, 06:10 PM   #915
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Very clean and looks great, and I have (lots of others also) have ground the piss out of calipers to clear bead locks and such when putting on massive brakes behind smaller rims

Why Ferrari red? Is that your inner redneck/ricer coming out?

J/k kinda ;)
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Old 04-10-2015, 06:10 PM   #916
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Any pictures of her....ugh...rear?
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Old 04-10-2015, 10:38 PM   #917
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Hey Bansil --- It's always risky to ask any gal about her rear...but...it is new too. Replaced the original 6.17 with a 1998 Chevy 3500 4x2 Dana 80 HD Duallie w/wide track that has 4.30 gearing for better highway performance and got disk brakes in the package. Given the old rear end was only good to about 45 mph, it really needed an upgrade. That worked out well as the Chevy wheels that fit the rear axle also fit the front with adapters I made. And in spite of being a "one-ton" compared to my original which was a ton-and-a-half...it is actually rated higher. 13,500 compared to 10,000.


Here it is being positioned.


And here it is bolted up. The old springs were also replaced with a set that has much lighter loading.

And yes...it was one heavy sucker to move about.

Still need to fit a mechanical disk parking brake onto the rear yoke but I think I've found what I need. Then, on to the two piece drive shaft.

Onward!
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Old 04-10-2015, 11:12 PM   #918
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Tango- Yea-I've ground calipers before on race cars. It seems like each rim company has a different idea where to put its bends. And where you ground is plenty safe. Another racing trick that might haved worked for you is wheel spacers.(But I don't know if your track needs to be fixed at a certian number.)
Is there a reason why you front mounted your calipers?
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Old 04-11-2015, 04:26 AM   #919
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looks good tango. you gonna be finished with her in a few days?
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Old 04-11-2015, 04:40 AM   #920
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Sweeeeeeeeet

I like it, think she will be drivable this summer?
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