13 inch Brakes - Caliper Bracket Machining

I missed some of the vid for the second OP, but it was pretty similar to the first side.

[@AmateurRedneckWorkshop]

Looks great. Keep on keeping on.

[@bluehandsvideo]

Thanks Harold! :)

[@HughesEarthworks]

Great job, the bracket looks awesome. Could you use the end mill to interpolate the holes on the first operation so you can chamfer the holes or not? I'm sure I'm missing something as to why you don't want to do that.

[@bluehandsvideo]

I may end up redesigning the part some anyway. I've got some tweaks in mind for the next set. :)

[@chrisstephens6673]

I was waiting for you to break another end mill or two, you let me done. :>)

[@bluehandsvideo]

Sorry....can't afford to break them all!! lol :)

[@TomZelickman]

Good progress, Mike! That's weird how you kept getting chatter on that back side only. Glad you got it sorted now though. Best wishes, Tom Z

[@bluehandsvideo]

Thanks! I'm sure the chatter will show up again....time will tell. :)

[@telissamantas6484]

did you thread on any of the holes?

[@bluehandsvideo]

Yes, I did. I used threaded inserts in the holes. The tapping is in this vid..... kzbin.info/www/bejne/sHfYqIZ6r9V8jcU

[@telissamantas6484]

Thank you for the prompt reply! Keep up the good work!

[@bluehandsvideo]

@@telissamantas6484 You're more than welcome. Thanks!! The biggest reason I didn't do more of those brake setups was because the rotors were over $200 each......not typically something Datsun truck guys would want. lol

[@Num1000Lock]

Great video. How did you machine it on two sides? Machined first side, turn part upsidedown that's clear. But how did you make sure everything is aligned for the other side?

[@bluehandsvideo]

Great question Tim.....and one I asked a lot! I'm using fusion360 for my final CAD and all of my CAM. Basically, I had to model the soft jaws along with the part. Once you get them over lapped in CAD, there's a combine function that will let you use the part as a cutting tool on the soft jaws you've modeled. When I model my SJs, I make sure to pick a spacing between them that I can duplicate....meaning I round the distance up or down to 1/8"....then I use 1x2x3 blocks and parallels to hold the distance when I cut the jaws. .....I just went and looked....the video just before this one addresses the soft jaws.....some...not completely, but it may help. kzbin.info/www/bejne/oKeafZWknKhlg6M This one is really long, but covers more of the CAD end of it. kzbin.info/www/bejne/p5LSf3egpdVpoNE Let me know if they help and if you still have more questions......I'll see if I can answer them......but keep in mind.....I'm not much more than a beginner with some of this stuff. :) Mike

[@Num1000Lock]

Thanks for the information! I also use Fusion360. Keep up te good work

[@Mr.SR_Mahajan]

What is thickness of that caliper

[@bluehandsvideo]

looks like this was posted twice....?

[@slicktires2011]

Nice job! which alloy is that?

[@bluehandsvideo]

6061-T6 Thanks!!

[@bluehandsvideo]

@@Zukuri620 Cost.

[@bluehandsvideo]

@@Zukuri620 I can't argue your points.

[@bluehandsvideo]

@@Zukuri620 Thank you. I'd like to think they're more than strong enough, but I haven't done any FEA on them. I think I can do it in Fusion, but I really don't know what loads to put on it. As you know, the trucks are pretty light and the larger diameter rotor should make the load on the caliper/bracket less than on the stock setup due to the increase in leverage. I'm still pretty much an amateur with fusion, but if you get stuck, I might be able to help or point you in the right direction. Which rear is the h233b? Late HB? What size rims are you going to run? Kevin has a great channel and has been a big help with fusion.... kzbin.info/door/lX2m8Uo6bJkqnRdoGJLcQQ

[@jamespufflecock6466]

I have the same exact problem with chatter in one direction and its is driving me nuts.

[@bluehandsvideo]

I've since heard from a couple more people that have the same issue. One has the same machine, but the others are different. What machine do you have?

[@jamespufflecock6466]

bluehandsvideo I have a much smaller Wabeco 1210 cnc machine. I initially thought it had something to do with column flex, but seeing you have the same experience with a much more rigid machine, I suspect the cause might lie somewhere else. I did notice that by removing backlash from the Y-axis balls screw thrust bearing I was able to reduce this kind of chatter, which makes me believe that the problem is caused by backlash in the Y-axis (nut and bearing)

[@bluehandsvideo]

The last time it was doing it, I pushed and pulled on the head, up/down/left/right and it didn't seem to help.....so maybe the Y axis needs to be checked. I'll do that the next time I get chatter. Thanks!

[@nevergiveup2365]

U make caliper brackets for cars?

[@bluehandsvideo]

I have made some for very specific applications....custom orders. I only do personal projects now.

[@RealGeeNius]

Whats the best metal for adapters?

[@bluehandsvideo]

I don't have the background to say for sure. I'm using 6061, but I'm sure 7075 would be better....just can't afford it. One customer just crashed his truck into a wall at 45 during an event.....bent the frame 3" and broke the ball joint carrier......but the cross shaft was unharmed.

[@trimbil3703]

Cutter HSS?

[@bluehandsvideo]

There were a couple of different ones, but they should have all been carbide.

[@Mr.SR_Mahajan]

What is thickness of this caliper

[@bluehandsvideo]

???? The caliper being used on this project? It's a wilwood caliper designed for a .810" rotor. Sorry if I'm not understanding the question correctly.

[@Mr.SR_Mahajan]

@@bluehandsvideo we are going to design ATV and out disc radius is 160mm we are taking the dimensions of caliper as 78x83x73 so what would be our adaoter thickness

[@bluehandsvideo]

@@Mr.SR_Mahajan No clue. It's going to be different for each rotor/caliper combo. Your caliper is going to have a completely different offset then anything I've used. This adapter was made to go between a factory Nissan spindle's caliper mounting holes and a WW caliper. I had to measure everything and design it in CAD in order to get the dimensions. It doesn't have to be done in CAD, but it was easier to do it that way for this project.