Rear disc brakes

[Justin]

I'm kicking around swapping in some Explorer rear discs since it sounds like they're the only swap that has a decent E-brake. I'm also aware that they're set up for the medium bearing rear ends. How hard is it to accurately expand the holes for my big bearing ends?

[phyler]

Justin, if you do these, I'd love to help/watch. I have all the parts in my garage to do this. Granted, my Bronco has the right rear end for it to be a bolt on. I've heard I might need a spacer though.

[Justin]

Can do! Good thoughts, anything else I might need for this?

[sykanr0ng]

I've seen billet steel "Torino" bearing ends on eBay for $60

Been wondering if changing them would be better than oval shaped holes or welding and drilling or .....

[Justin]

The challenge with those is that you need an alignment bar to install them correctly. The long term dream is to build a 9"/14 bolt full float hybrid, so if it isn't easy I'll just stick with drums.

[Kinder]

I'd say you could just "key hole" the existing bolt holes and you should be good.

[Justin]

How close do the tolerances need to be.?

[phyler]

Justin, if needed, I can loan you a backing plate so you can see what it might need.

[Viperwolf1]

I think the lack of enough axle brake offset is going to be the bigger challenge.

[Justin]

So do the brakes need to go out or are longer axles needed?

[Viperwolf1]

So do the brakes need to go out or are longer axles needed?

Larger distance from bearing to WMS unless you use the '76-'77 axles. Those should be about right.

[Justin]

I'm using an axle out of a 77 F150. How much longer do the axles need to be over stock?

[Viperwolf1]

I'm using an axle out of a 77 F150. How much longer do the axles need to be over stock?

Oh that's right. Those might actually have the right offset. Should be about 2 3/8". The early heavy duty axles were only 2" offset.

[Justin]

As measured from the axle end to WMS?

[Viperwolf1]

As measured from the axle end to WMS?

Yes.

[Justin]

OK, I ate lunch at home and popped a drum off to measure. Looks like you're right. I'm seeing a hair more than 2 3/8 from the backing plate to the face of the axle. If I move forward with this, it looks like all I'll need to do is figure out whether my existing e-brake cables will work and open up the mounting holes. How precisely do those holes need to be cut? It seems like a paper template could be used to mark it and a die grinder used to carefully expand the existing holes.

[Viperwolf1]

Use a bearing retainer for your template. You could even tack an old bearing to it to keep it centered.

[Justin]

That's a darn good idea. Thanks!

[sykanr0ng]

Over on CB there was a thread about the possibility of 2004-2007 E-150 van rear disc brakes being workable.

Would need at least 16" wheels.
Rotors already 5 on 5.5
Bigger diameter so maybe better parking brake?

Food for thought for the junkyard spotters?

[BroncoCrawler]

Opening the center of a backing plate is pretty easy. I did it on my girlfriends TJ when I put grand Cherokee disks on her jeep. Of course I used a Bridgeport with a boring head. (My dad has one)I'd be happy to take a crack at this since for you but unfortunately it would have to be after June 23rd when I return from my Rubicon trip. I'm in panic mode trying to get everything ready currently.

[plumbdoctor]

I just keyholes the holes , center of backing plate was fine, I used explorer parking brake cables. One thing to keep in mind is to clearance the center hole of the rotor, and the axle end. Mine machined 1/16th so they would fit inside the rotors.