Plumbing brakes on a truggy

[Baja Burley]

How do people plumb their brakes?

I've got a hilux truggy and just finishing off putting cruiser diffs under it. The rear brakes come from that proportioning valve on the rear of the chassis. There is enough chassis left to bolt up the valve but is there a way to get rid of it? The brakes were shit before we cut it all up and it would be good to improve them.

I've looked into discs for the cruiser diffs but it's out of the budget and too much work. Can I replumb the brakes using the lux master and most of the lines?

[evanstaniland]

so you have gone to the effort of building a truggy so you can wheel harder stuff but you dont want it to brake properly?
drum brakes are shit. if cant afford new brakes why dont you look at wrecker parts to put discs on?
you only have one life and safety should be high on your build list. propper tube, harnesses, brakes etc shouldnt be scabbed out on. Motorsport isnt cheap

[Baja Burley]

From reading about others rigs I saw discs as more of an upgrade and not a necessity. Drums can be set up to work well in the rear, especially with very little weight in the rear such as my truck. Correct me if Im wrong... I do not wish to die.

Back to the original question.. Is there a way around the proportion valve?

[evanstaniland]

to answer your question. take it out.
i wouldnt use drums ever for the pure fact they are so easy to be affected. mud fucks them out. and discs are cheap enough from wreckers

there is no valve between the MC and calipers in my truggy

what diffs?

[Baja Burley]

Thats what i"m hoping to run - straight lines to caliper. But worried about distribution and rears locking up.

Diffs are 40 series. Front will have all the hilux knuckles with highsteer and discbrakes put on it. Rear is now up in the air.

I do know 60series came out with disc rear at some stage but dont know how available those parts would be...

[Rhett]

In a four wheel drive, with it in four wheel drive, you have no chance of the front and rear locking up in different times. They are linked together with gears and shafts. Unless you have a centre diff lock unengaged.

[Fakey]

99% sure there were no factory disc 60s (someone will correct me if I am wrong haha). Its stupidly easy to fit lux discs onto a Fj40 full floating rear diff. Google is your friend. All I used on my one was early solid axle hilux discs an calipers. Made a bracket to attach the caliper. To attach the disc to the back of the hub I used SFA lux front wheel studs with a hardened washer under the head of each stud to get the shank spacing right. It needed an adjustable proportioning valve to get the brake balance right tho

[Baja Burley]

God I feel like an idiot now... Of course you can't lockup one end

So did you just pull the drums off the hubs as replace with discs? What was the reason for using The hilux studs? Then the discs are centred around the studs and fastened by the wheelnuts?

I have a set of discs and calipers sitting on the parts truck that would be so EASY to use
Is there anywhere that sells the caliper brackets to suit Lux discs to 40s diff? Only problem is I have a huge diff brace on the rear. Do you have any pics of yours fakey?

[Baja Burley]

What's the handbrake solution with rear discs? Is it possible to have a Tcase brake AND a rear shaft disconnect??

[evanstaniland]

You can put in a hydro handbrake

[Jack S]

Which is?
Can you explain a little more?

[Baja Burley]

Is that basically a line lock on the rear?

[evanstaniland]

No line locker is a line locker. A hydro hand brake is what drifters use google it or look on ebay. But I'm not sure how good they will work on drums? I'd still be changing to discs

[SierraDan]

Its like pushing the brake pedal down to apply brakes.

But, with a handbrake handle and it only does the brakes you plumb it into.

[Jack S]

Is this a hand brake setup that tuff truck or CCDA will approve and be happy with?

[SierraDan]

I cant see why not. They approve line locks and modified cutting brakes.

[Baja Burley]

We pulled the hubs out of the 40s drums and tried to fit a standard front ln65 disc on the hub and the centre circle is too small on the disc, by maybe 2-3mm. I'll see if its worth machining out in the next few nights.

Regarding that handbrake, We though we could fab one from a clutch cylinder? how would we plumb the end line to the rear brakes?

ie. The caliper only has one port to connect a brake line, which is used by main pedal brakes. IF the line from this hand brake is to intersect that line somewhere; this would pressurise the main master cylinder and over flow it wouldn't it?

[Baja Burley]

Update on the Hilux front calipers onto 40s floating rear: NOPE! They will fit with some maching but im not sure its worth it
1. The inner clearance on the wheel mount surface of the disc is about 5mm too small to slide over the bearing housing part of the hub
2. The outer diameter of the wheel lug flange on the HUB is about 10mm too big to slide into the back of the disc..

I have been searching around Ih8Mud and found they use a common 'GM disc conversion'.. Whether their 'GM' parts are available here I have no idea. I also saw one tech write up and saw the 40diff he had wasnt a floater. Did they have floating diffs in 40s and 60s over there or am I reading in all the wrong spots?

Surely this conversion is common here in Aus with wreckers parts.

Luke

[evanstaniland]

Will 80 series disc and hubs bolt on? Or 60?

The hydro hand brakes are $60 not worth fucking around making one!

[4_low]

Will 80 series disc and hubs bolt on? Or 60?

The hydro hand brakes are $60 not worth fucking around making one!

For $60 you could get two of these and mount them side by side for cutting brakes, A lot cheaper then cnc cutting brake setup.

[Baja Burley]

Yeah that's true Evan, I'll try to source one and plumb it in.. Does anyone know the answer to plumbing it though? I highly doubt a T joint into the rear brake line would work..

I don't have any other discs to trial fit... So have no idea what else might fit..


Is the 40s rear a full floating or semi floating? I would have thought semi because one end is still fastened. But I can I only find literature on full floating rears..

[Baja Burley]

Well it turns out it's pretty common to use the lux discs and machine me to fit so I'll go down that route.

After researching the hydro handbrake.. From what I understand - the rear brake line from the pedal master cylinder goes "through" (into the IN and out the OUT) the handbrake MC and onto the rear caliper. That way the pedal brakes still work mainly unobstructed, the handbrake can be used independently and then only acts as an "inline booster" when applied at the same time as the pedal brake..

Anyone see any issues?

[evanstaniland]

You plumb it in line so from MC into hydro hand brake then to rear calipers.


You don't need 2 for it to work as a cutting brake. Plenty of rigs dig with both rears braked.

[Jack S]

Anyone got a link for the handbrake above?

[4_low]

Anyone got a link for the handbrake above?

http://www.ebay.com.au/itm/Hydraulic-ha ... 57b&_uhb=1" onclick="window.open(this.href);return false;

there is plenty on there

[Jack S]

How do you work out what what brake booster, pedal etc etc is needed?

[evanstaniland]

Booster, pedal for what?

[Jack S]

Just ordered the above setup, wait and see the quality, but will be a while till its in use!

A tuff truck style rig, using dana 60 front and sterling 10.5 rear...

[evanstaniland]

The hydro handbrake is for dig and parking.
Matt Meddows runs a commodore booster and MC on his d60 and d70.
I'll be running most likely run cnc mechanical brakes

[Jack S]

I have a comodore booster here I was going to use (1 1/8" bore I believe) but have about pedal and resiviour?
Or is it best to just go a cnc/willwood setup?