Toy rear disk conversion - Depot style

[Depot]

Well I finally got around to posting all these pics so here goes. Fulload and I did this on my rig last year....

Step 1 - remove Drum

[Depot]

2 - remove all braking components - get down to a bare backing plate

[Depot]

3 - I opted to practice my torching skills and torch off the backing plate around the flange instead of using a sawsall.

[Depot]

heres the piece that landed..

[Depot]

and a close up..

[Depot]

Depot's brackets.... (thanks for the hold up Full)

[Depot]

I made 4 brackets for practice... I used 3/8s plate steel as I found it lines up perfectly with my axel flange and location of caliper. no bending, no drilling, just welding. This approach adds a lot of work to the process and U'll see later but I think its worth it...

[Depot]

finished brackets, all cleaned up with the 2 slider bolt holes drilled and tapped.

[Depot]

loaded caliper mounted to bracket and placed in place for sizing

[Depot]

look from backside while sizing and fine tuning.. required a bit more grinding along the middle of the bracket along the bottom to fit tight over the hump in the flange... Some toy axels are flat and some have that hump between the bolts.. dunno why.. dont care :)

[Depot]

Bracket tacked on.. removing bolts that hold axel bearing in...

[Depot]

removed c-clip that holds bearing retainer in and pressed out the bearing and retainer in one shot..

[Depot]

here u can see both axels removed from bearing housing.. both caliper brackets welded on solid and cleaned up. If u look close u can see one bearing housing is upsidedown to give yah views from both sides.

[Depot]

place new bearings inside housing and press back onto axel. I used a piece of 1 1/4 shed 40 pipe which fits nicely over the axel and presses the bearing down on the inner race. Looks like toy axels are the biggest u can stick in a princess auto press before u run outta space....

[Depot]

or so i thought..... turns out one of the studs cought the corss memeber along the bottom of the press and a few tons of pressure later.. BOOM... press sheared the gr 5 bolts that held it together... what a bang that was! lol

[Depot]

pressed on the bearing retainer the same way, did same for both axels and reasembled with new seals and lotsa rtv...

[Depot]

final look... all lubed up...

[Depot]

some of the parts I used for this build... I have part #'s at the shop if anyone cares for em...

Rotors - 88 chev 1500 reg cab reg duty - center holes machined out to fit over toy center ring

Calipers are off a sonoma front 4x4 - forget what year off hand.

master was upgraded to a cherokee - direct bolt on.. use the cherokee pluger which has adjustments on it to get the throw in the right spot.

No Proportioning Valve! the cherokee master has 2 chambers.. large one used for front brakes with a T splitter in it... small one used for rears with another T splitter. Sure my rears lock up b4 the front but only under heavy braking or on real loose dirt roads. thing works mint!!! heres one last pig from the mohawk fair fullload and I did last year...

[zc911]

nice work

[Terranaut]

Very nice !
A Cherokee master will bolt up to the Zuk brake booster or did you use the cherokee booster as well?

[Depot]

wagoneer.. bolts directly to the zuk booster - add an o-ring between the 2 to seal em up and adjust the push rod... took me about 5 tries to get it at the right setting for pedal travel.

D

[MLC]

you the man