Ok here is more info for those that are interested...
Now I had a few rider with my install.
Parts must be off the shelf or with very minor modding.
This is cause I didn't want to get out in the sticks and have any issues getting parts to get me home.... So when you read on you will get the idea.
Parts list
Calipers from Subaru Leone, Front. Larger disc model.
Rear discs from a Nissan GQ (the ones with internal handbrake)
Some have already done this mod on various trucks but none to date on the Playdoh... Or from what I have seen.
One of the previous mods was to use the front disc from a landcruiser and machine away the edge of the rear drive flange to make it fit over...
I didn't like this approach as if I stuffed a rear drive axle I would need to mod one rather than just shove a replacement unit from a wrecker bolt it all up and off I go.
Here is my approach...
Remove rear axle assy's and cut off handbrake backing plate.
Save the mount bracket for the brake hose ! We will use this later.
Save the brake hoses.
Get a pair of Nissan rear discs and open the holes up for the studs to fit... Nissan studs are smaller than Toyota... If you ever stuffed a disc its easy to open some holes up at a local garage / workshop.
Now the center hole is larger on the Nissan disc so to achieve centering I had some rings made up and slipped them onto the drive flange. They effectively stay with the flange... Again if caught out you wouldn't need to swap these over for a dash to home....
The calipers them selves have had some adjustments to them.
The handbrake levers have been swapped from left to right and also installed from the opposite side....
This allows the lever to clear the chassis and also gets it close inline with the factory handbrake cables.
And also the position of the arms has been adjusted by un stitching the weld, rotating the arm and re welding. Could also do it by cutting a bit off and re weld on a new arm. Pictures later will explain it all....
The calipers have been positioned behind the axle as apposed to the original caliper position in front. The Subaru caliper wont fit in front as the shock gets in the way with the handbrake mechanism.
Also they have been positioned to miss the chassis when on the bump stops and the chassis is articulated. Particularly the sway bar attachment point on the drivers side.... If you have a drop bracket this install may not work as its rather tight in there.
The other mod to the caliper is its mount cradle. It needs a little material removing from its throat to allow it to sit deeper in the disc.
Lastly the pads will need a smidgen shaving off them so as not to overhang the disc...(Cert requirement)
Now the pads on the Subaru are bigger in surface area than that of the original Toyota ones... so losing a bit wont effect much.
The other thing to note is the piston is slightly bigger on the Subaru... so will have more clamping force.
Now earlier I mentioned to save a few things from your old setup...
The original brake hose from the right hand side fits perfectly on the left caliper. And likewise for the other side.
The two hose brackets from the old backing plate once flattened out make for good hose mounts tack welded to the axle housing....
The only thing I haven't done to date is to test out the handbrake cables.. As the trucks body is not on its chassis...
I suspect they will not pull enough...Simply by its design... But I have a cunning plan to adjust the lengths of the factory cables to make it work.... However the jury is open on that one..
Note: These are fitted with 15 inch steel rims... with custom back spacing. I will need to check my std 15 inch rims to see if they fit... So hold that thought ...
Now onto some pictures...
- Disc with spacer
- Calipers
- Caliper handbrake Levers
- Bracket left
More in next post