Disc Brake Conversion / Knuckle Grinding Mod Question

I'm glad your were in your shop, also. We shouldn't ever 'Try-out' our skills on any brake system's. Too dangerous for everyone, IMHO. I used Horsepower in 2019 . They invented, or at least perfected , the system. GM parts is what I've always gravitated to. I've also all way's respected the mechanic's relationship between Jeep & GM.
I am happy that you learned & shared this lesson & that no one was hurt.

 

I suspect the "Chevy Caliper" is simply too vague of a description for consistent results with different variables like...
Differing regional parts venders.
Various manufacturers.
Different year and trim donor vehicles.
Allowing some to fit without issue, others take slight rework and others... not so much.

I'm glad it happened where it did and not anywhere else for no place is a safe place for brake issues except the garage, with wheels chocked and nobody else nearby.


someone was watching you

 

When i did the disk conversion on my d27 i redrilled the caliper mount to reclock the caliper to the 3 o'clock position if looking at the driver side. It didnt take much grinding the the knuckles. I replaced the stock fill plug with a flush mount allen head plug.

Its better to have the calipers fail in the garage than on the road. I might have missed it but why are you hesitant to grind on the knuckles but your ok milling material off the calipers?

 

It was over a year ago, and back then I had a romantic notion of trying to leave as much unmolested original parts on the Jeep as possible and only modify new parts. The reality of the project quickly made me realize that was a pipe dream that didn’t matter.

 

Brad is back, Welcome back Focker.

 

I get it. Been there, done that. I hate seeing decent jeeps parted out when someone just needs to make a part or go through some effort.

 

sorry but the Truckee setup is simply a version that has been sold for many, many years by many, many vendors. Slightly grind the knuckles and move on. Been covered here Many times. You can also go with he R&P 1/4 ton kit that requires no knuckle grinding and no bearing hub machining since the rotors slip fit on the outside of the hub. These have been available for years.

 

Have you talked to Sam? No grinding with his kit.
https://stores.partsdude4x4.net/disc-brake-conversion-kit-dana-25-27-closed-knuckle-deluxe/

 

This didn't seem that slight to me. I was obviously wrong.

Yes, I talked to him about it about a year after I bought the Kaiser Willys Kit and found out about the Horsepower kit. And Brennan's etc. I didn't want to throw money away and tear the axles back apart. Look as I have said repeatedly before, I have never done a restoration/modification project on any vehicle before. So this is one of the many many mistakes I've made and learned from.

 

Some have been doing it longer, and still have the occasional "oh crap" moment. (I know I do). And kudos for being transparent about it, and we all learn from mistakes made.

 

Yeah Sam told me about his kit in 2020 and I did nearly kick a tree when I left his shop...The $900 KW kit was one of the first parts I bought in 2018 when I decided to tear the Jeep apart and I think I installed it the year after that when I was in the axles.

After I had the backing plates, rotors, hubs and bearings in I just didn't want to go backwards and drop another $750. As I said - my dad taught me carpentry not cars so even the success of pressing the wheel studs in was a major accomplishment for me. It seemed like a worthy challenge to try and mod the KW calipers like Horsepower does and learn some milling on the Bridgeport, but obviously (as other have said above) this is an area (brakes) where mods are done at much risk of peril.

Looking at my Jeep now and how much other time, blood, sweat, tears, and treasure have gone into it, at this point I just hope I can get the replacement Horsepower callipers safely installed and bleed the system and make it safe. As my wife reminds me when I get frustrated - this entire project was supposed to be about learning. And failure (at least the kind where you don't drive into a tree) is the best teacher.

 

Thank you for posting what you learned in this process. Honestly the calipers are relatively cheap and an easy swap. It would be a lot more work to replace a knuckle.

Here are what my knuckles look like with Redrilled brackets and how they put the caliper in the armpit of the kingpin bearing and drain plug. I only ground what was needed with new pads and pads that are worn down.

20220205_143621 by Joe with a jeep, on Flickr
20220205_143717 by Joe with a jeep, on Flickr

20220205_143545 by Joe with a jeep, on Flickr

I don't expect these pads to wear down fast so you can easily keep an eye on the clearance and hit it again with the grinder.

 

Well I got them on, now all that’s left is to rip up the carpet, see if I can get that port off and re-bleed the brakes and see if the pressure holds.

 

Oh, the carpet-damn. Can you leave a hole and install the cover over it so you don't have to pull it up every time?

 

That is definitely happening

 

You know, thinking back, my dad once rigged a remote reservoir on the firewall for the MS. Maybe an option.

 

On the single res master you can drill out the vent hole and tap it then run your remote from there. With the dual reservoir you will need to pull the master cylinder off to drill and tap the side of the reservoir as high as possible without interference with the lid or seal.

 

I love this idea....wish I had heard about it a few months ago. I can barely reach my hand in the hole and pop the lid to snake a funnel and hose down into the tanks of the dual res I installed.

I don't need to re-bleed the rears as well, do I? The level in the rear tank is still full.

 

shouldn't have to, but do it anyway. it's open you're at it, and it's free.

imagine buttoning it all up to only have to take it all back apart.

 

Yeah good point.