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post #1 of (permalink) Old 11-20-2000, 07:06 PM Thread Starter
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Nearly finished disc brakes

Figured this would be an easier way of gettin' these out. I'll spare you the actual build-up details, but instead tell you what we did different.

First is the finished mount from above.

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post #2 of (permalink) Old 11-20-2000, 07:16 PM Thread Starter
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Re: Nearly finished disc brakes

This is the modified backing plate. We did the notch thing suggested in the BC4X4 write-up. Makes axle replacement easy, makes spares smaller and helps drain water away from the bearing. Some axles we seen had silicone on the backing plate, but water got in from around tha axle and rusted the bearing out. This mod will keep it clean and let it dry.

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post #3 of (permalink) Old 11-20-2000, 07:21 PM Thread Starter
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Re: Nearly finished disc brakes

Now for the pre-90 dual rear brake line era, you can skip this.

But if you are like me, ya need to do sum fabrikatin'. We took an old front Tee block and cut it in half, giving each half a mount hole (see pic).

Next we moved the location where the brake hose meets that axle near to the top of the pumpkin. From there we ran to the Tee block and split to each side. We welded a bolt to the pumpkin to fasten the Tee to.

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post #4 of (permalink) Old 11-20-2000, 07:24 PM Thread Starter
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Re: Nearly finished disc brakes

Dammit. Here it is

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post #5 of (permalink) Old 11-20-2000, 07:34 PM Thread Starter
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Re: Nearly finished disc brakes

Here's the back of the caliper. This was our own mod. We didn't like the length of the front hoses. So Bob CAREFULLY cut the bango fitting "cage" off and used the hoses from the front Tee block (much shorter). We also took the said hose bracket and cut that in half for use on each end of the axle tube.

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post #6 of (permalink) Old 11-20-2000, 07:40 PM Thread Starter
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Re: Nearly finished disc brakes

Doh! Photo?

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post #7 of (permalink) Old 11-20-2000, 07:46 PM Thread Starter
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Re: Nearly finished disc brakes

Here it is with the caliper and rotor on. Notice how the hose is tucked out of the way but will allow the caliper to move.

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post #8 of (permalink) Old 11-20-2000, 07:50 PM Thread Starter
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Re: Nearly finished disc brakes

Another view of it all together

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post #9 of (permalink) Old 11-20-2000, 08:03 PM Thread Starter
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Re: Nearly finished disc brakes

Now my solution to the loss of rear e-brake, the SJ410 e-brake. Notice the drum. It's center hole, where the drive shaft flange mounts, needs to be machined to accept the SJ413 driveshaft (hole too small). The hole pattern is also smaller than the early SJ413 pattern. Turn 90 degrees and redrill. Re-insert studs.

For the large flange bunch like me, get a spare drive shaft of the older small flange ilk. Swap the flanges so you have a small flange on the slip yoke and a large flange on the axle end. Now it works and you have an extra shaft 'cuz few on the trail will have an extra set up like what you'll now be running.

We'll update you once we get new shoes. We got the new shoes blues! [img]/wwwthreads_images/icons/crazy.gif[/img]

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post #10 of (permalink) Old 11-20-2000, 11:17 PM
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Re: Nearly finished disc brakes

Chris Minerich recently helped me build this setup for my Zuk, ORC's Project Buster. We just wrote an article on this conversion, which will be up for the December issue of Off-Road.com. Hopefully it'll make the main Table of Contents, if not it'll be in the Suzuki TOC.

--Geoff Beasley
Suzuki Tech Editor: http://www.Off-Road.com

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