Toyota Tacoma Forum banner

241 - 258 of 258 Posts

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #241 ·
As usual, I couldn't wait to get a mod done, so I've gone ahead and installed the bracket.

Before(rusty and crusty):
20210326_154706 by Jose, on Flickr

In between, I removed any rust left on the battery and radiator support using a rag dipped in motor oil.

After(new hotness):
20210326_155801 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #242 ·
The adjusters on the bottom of the bracket are sweet; they really let you get a proper hold on the battery.
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #243 ·
Alright, hopping back on to the 8.8 swap project: I found an old lug stud and lug nut I had laying around and had never used. I got this back in the day because some shop had overtightened my lugs and a couple broke when removing the nuts afterward. I never got around to using it since I bought and installed the extended studs instead. Using this allowed me to tighten the rotor onto the axle nicely, with the 3D printed studs helping to support and center the rotor.
20210329_141921 by Jose, on Flickr

With the rotor fixed in place, I was able to place the caliper on the rotor and take enough measurements to generate this bracket
20210330_145715 by Jose, on Flickr

I used this bracket to determine where the mounting surfaces on the caliper and the axle would sit relative to one another. That allowed me to take enough measurements to design this caliper bracket
20210330_145732 by Jose, on Flickr
20210330_154228 by Jose, on Flickr

Using this, I took more measurements and realized I had to make minor adjustments to move the caliper further up and make a couple of other slight tweaks. Keep in mind that the real bracket will be of considerably thicker material, this test is printed at 0.10" in order to save on printing materials. Once I have all the dimensions figured out, I will print templates and trace them out onto 1/4" steel sheet.
20210330_154510 by 20210330_154518 by Jose, on Flickr
Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #244 ·
I made the needed adjustments to the design and went ahead and printed one at full thickness. This allowed me to fully mount the caliper and verify the fitment of the caliper is proper. I am now happy with the bracket design and can begin the work of transferring it onto steel sheet. Of course, the hardware in the pictures is not what I will be using in the end, those are the bolts that held the calipers in the Zl1.
20210331_145523 by Jose, on Flickr

20210331_145506 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #245 ·
Currently printing templates of the bracket to trace onto steel plate. I may end up getting these laser cut once I am happy with everything.
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #246 ·
While I am cleaning up the battery area, I figured I may as well replace the broken positive contact cover. This had bothered me for years whenever I would work on or around the battery area. Unfortunately, I would forget about it once the hood was closed. As they say, out of sight, out of mind. Well, no more. I couldn't let that blemish take away from my new battery bracket. I found a the cover for sale on Ebay, being sold by a Toyota dealership of all places. $12 well spent.

Here is the new part and part number in case anyone needs it
20210402_143119 by Jose, on Flickr

Out with the old
20210402_145613 by Jose, on Flickr

In with the new!
20210402_150326 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #247 ·
Got the templates made and traced the design onto 0.25" steel plate. I drilled the holes out on the drill press yesterday.
20210402_160404 by Jose, on Flickr

You can see they line up perfectly to the holes on one of the prototype brackets I made
20210402_160356 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #248 ·
Got the basic shape of the bracket components cut out today using the angle grinder (which totally sucked to do). I will finish the shape tomorrow using a bandsaw and benchtop grinder. Unfortunately, both of these tools currently still reside at my parents' house (I need to make room in my garage for the bandsaw and I need to buy my own benchtop grinder).
20210403_201305 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #249 ·
Paid a visit to my parents today. While I was there, I took advantage and ground the brackets to final shape on their benchtop grinder.
20210407_153002 by Jose, on Flickr

Here is what the final assembly will look like in metal
20210407_155758 by Jose, on Flickr

Here are the parts progressing slowly (I would take breaks and switch which piece I was working on; they would get really hot and I forgot my gloves)
20210407_155812 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #251 ·
I guess I'm a proper surgeon with a grinder. Can't wait to get some CNC machines so I don't need to perform so many manual surgeries though lol!
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #252 ·
Just put in an order for all of the hardware I will need for my brake brackets and calipers. That, and some slightly thinner metal that I need in order to properly space the bracket. Once that comes in, I can weld the brackets together and install them on the axle.
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #253 ·
I got some slightly thinner metal sheet that I ordered for the brake brackets. Managed to make the final spacer pieces needed. Tomorrow, I plan to assemble the brackets tightly just using bolts and doing a test fit of the caliper. If I am happy with it, then I will weld the bracket together.
20210412_233319 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #254 ·
I was finally able to test fit the calipers using the metal bracket. For whatever reason, despite all my other hardware arriving from McMaster, the 3/8-24 nuts I need to hold the brackets to the axle won't come until early May. Of course, Lowes and Home Depot don't carry the fine thread stuff so I was stuck for a bit. Luckily, my local Autozone had them. There was literally one pack left and it only had 4 of the 5 nuts it was supposed to bring. Clearly some dude couldn't be decent enough to fork over the $3 for the whole pack he needed and he just stole one smh. Oh well, I only needed three for my test fit and the missing one got me a 10% discount lol. I wish I had thought to forget what Ford used on their stock bracket and simply used the closest metric bolt to the hole size, an M10.

Anywho, it is nice to finally see the caliper mounted with the metal bracket
20210415_152819 by Jose, on Flickr

20210415_152821 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #255 ·
It initially looked like the caliper wasn't properly centered above the rotor, but a quick adjustment got it set right. If anything, I can also add a thin washer between the caliper and mounting bracket to shim it out slightly. We will see where everything ends up once the bracket is welded together.
20210415_152833 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #256 ·
Once the brackets are done, I can clean and paint everything, including the calipers.
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #257 ·
I've been making some progress with the brackets lately. Mostly just massaging them with a hammer so they sit straight. I've got the caliper centered almost perfectly over the rotor. Unfortunately, it is still at a weird angle. Looking at it from the front, the bracket tilts outward so I will need to fix that. I would love to just have one machined from a solid billet so it would automatically be true.
20210420_172159 by Jose, on Flickr
 

·
Registered
Joined
·
2,636 Posts
Discussion Starter · #258 ·
I forgot to mention that I welded the brackets this past week. Unfortunately, I didn't get any post weld shots, I just went straight to the bench grinder and smoothed them out. Here's my weld setup though.

I clamped all the metal parts in the vise and then cut grooves where they meet by using an angle grinder
20210416_180314 by Jose, on Flickr

Did the same thing on the underside
20210416_180330 by Jose, on Flickr

Here's a top part after welding the underside. I pretty much took this one, post weld picture because I loved the blue and purple colors that came out.
20210416_181333 by Jose, on Flickr
 
241 - 258 of 258 Posts
Top