Disc brake conversion project started

Mopar_Earl · 08-16-2019, 10:50 AM

Finally after 1.5 years I'm getting around to installing hydraulic disc brakes on my 2017 Eagle 293RKDS with 6k axles that I bought. Kodiak disc kits with a Hydrastar actuator. Running nicopp brake tubing with SS stone guard. SS lined p-clips. SS line nuts. My tubing is 1/4" for faster response time. Then 3AN to 3AN SS DOT hoses to the calipers. Running #8 power wiring from the batteries to the actuator. The other two wires will be #10 from the pin box, brake and break-away. Power circuit will be off the truck charge line and the trailer batteries. 40A auto circuit breaker off.

I have the Hydrastar actuator mounted. I choose to mount it as close to the axles as I could. Originally I was going to mount it behind the entry steps on the frame rail. Would of put it right near the front axle. But I wanted the addon extra capacity reservoir. That made the actuator too tall to mount there. So I mounted it in the basement behind the service access wall. That way it's as close to the axles as possible and protected from damage. I wanted the extra reservoir so I could see at a glance the fluid level. Also the more fluid the better off you are if you have a small leak occur. The extra fluid will dissipate heat as well, not to mention longer bleeding sessions.

I mocked up one disc brake assembly so I can figure out my SS hose lenght. Ordered those this morning. I already pulled a 10/2 cable from the pin box to the basement for the brake and break-away circuits. Today I will pickup my #8 power wiring.

I bought US made Timkin bearings and races. National double lip spring loaded seals. The disc kits came with no name china bearings, races and seals. No thank you, I will use better.

The drum brake I took off had paper thin lining and the drums magnet surface badly scored. Wouldn't of passed state inspection. Curious what the other 3 will look like.

Once I get the brake hoses I will start installing the disc kits. Then running the brake tubing.

No more work on the project till Monday. Then I plan to run my #8 power wiring and start removing and installing the races in the rotor hubs. Will keep on keeping on till the hoses show up.

Earl

Mopar_Earl · 08-16-2019, 11:06 AM

Previously I added a 7-way junction box at the pin box. Jayco had a big ball of tape with all connections wire nutted or crimped. Now it's a nice junction box. Which will make it easy to terminate the 10/2 wiring for the actuator. I also put a studded ground bus inside the pin box frame to secure all the grounds. Apparently Jayco terminated every ground in the front part of the trailer to the pin box frame in a wad of crimps and tape. That's now terminated to the bus bar nice and neat with a #8 bonding the bus to the frame for frame grounded items.

Earl

klassic · 08-16-2019, 08:14 PM

Love it.
How about some pics.

Magnolia Tom · 08-16-2019, 08:52 PM

Quote:

Originally Posted by klassic

Love it.
How about some pics.

I guess it didn’t happen [emoji1787][emoji1787][emoji23]

**JFlightRisk** · 08-16-2019, 10:33 PM

I've GOT to get Earl to move next door to me!

Mopar_Earl · 08-17-2019, 04:47 AM

Picked up my #8 power wiring yesterday. I use the high amp capacity wiring they use for car stereo amps. Great stuff. Gotta buy the good stuff though. Like everything else, there is cheap junk on the market.

Brake hoses were made yesterday and shipped out. Looking like maybe Monday for delivery.

Earl

Mopar_Earl · 08-17-2019, 04:53 AM

Couple pics I have on my phone. One showing the paper thin shoe lining. If you look closely you can see it breaking away on the edge by the backing plate. A pic of the scored drum where the magnet rides. A pic of the actuator in the location but not installed at that point. You can see the extra capacity reservoir. Then a pic of the disc brake installed to mock up for brake hose lenght. I will take more pics as I work on it.

Earl

AKRUEBBE · 08-17-2019, 07:23 AM

Quote:

Originally Posted by Mopar_Earl

Couple pics I have on my phone. One showing the paper thin shoe lining. If you look closely you can see it breaking away on the edge by the backing plate. A pic of the scored drum where the magnet rides. A pic of the actuator in the location but not installed at that point. You can see the extra capacity reservoir. Then a pic of the disc brake installed to mock up for brake hose lenght. I will take more pics as I work on it. Earl

Earl, how many miles are on those shoes?

Mopar_Earl · 08-17-2019, 07:46 AM

Quote:

Originally Posted by AKRUEBBE

Earl, how many miles are on those shoes?

Not many. I keep track of the miles. Will have to calculate my numbers. The top tech at my dealer says they always get complaints with Lippert brakes for being weak. He said he believes the lining compounds aren't up to standard. I can believe it. As weak as the drum brakes are and the lining failing so early. I will post the mileage once I calculate it. I will also post what I find when I pull the other 3 apart.

When I did my wet bolt kit, my plastic bushings were bad and two never installed. 3 worn completely through. That was at 4800 miles. I also installed the Moryde x-factor hanger cross members.

FYI, I did ponder replacing the drum brakes with better quality Dexter brakes. But had OT burning a hole, so I said screw it, going disc.

Earl

Mopar_Earl · 08-17-2019, 05:47 PM

Quote:

Originally Posted by AKRUEBBE

Earl, how many miles are on those shoes?

Little over 8k miles on the trailer.

Earl

Mopar_Earl · 08-18-2019, 07:26 AM

Here is a pic of the Hydrastar actuator installed. In the pic is a trailer 7-way junction box. I had one laying around and using it for the actuator connections. I will mount it on the wood framing by the actuator once the wires are landed.

Earl

Mopar_Earl · 08-19-2019, 01:49 PM

My DOT SS braided brakes came today. The guy did beautiful work. Black whips and black protective covers. -3AN fittings. Almost too sexy to install. Lol

Today I've been running my #8 power wires for the actuator. Also the #10 brake and break-away circuits to the actuator junction box. Now that the hoses came, I will mock one up on my mocked up disc assembly.

Earl

Mopar_Earl · 08-19-2019, 02:09 PM

Hoses will work beautifully. Here I have one mocked up.

Earl

klassic · 08-19-2019, 04:09 PM

Oh ya. I like those.

Dargo · 08-19-2019, 07:18 PM

This is awesome. On my someday list.

Mopar_Earl · 08-20-2019, 04:57 AM

Yesterday I got all my wiring ran and landed. I also pulled some extra pull strings to the pin box for any future needs. Mounted my 7-way junction box for the actuator. I'm down to installing the disc brake assemblies and installing the brake tubing and hoses. Need to run to Lowe's to get some SS hardware to mount my 3AN blocks on the frame rail and for my SS p-clamps. Also need to drive out the china races and install the US races. Pack and install the bearings and seals into the rotor hubs.
Slowly but surely.

Earl

Mopar_Earl · 08-21-2019, 03:31 PM

Today I made some progress. I got the road side brake tubing done and brake hose blocks. I cut and flared the nicopp to lenght. Installed SS stone guarding. Secured line with SS rubber insert p-clips. Tomorrow I will do the other side and the brake tubing that will join the two sides together.

Earl

Dargo · 08-21-2019, 04:35 PM

Quote:

Originally Posted by Mopar_Earl

Today I made some progress. I got the road side brake tubing done and brake hose blocks. I cut and flared the nicopp to lenght. Installed SS stone guarding. Secured line with SS rubber insert p-clips. Tomorrow I will do the other side and the brake tubing that will join the two sides together.

Earl

Looks like you are doing a job that will last forever. SS coil around the brake cable.

Mopar_Earl · 08-21-2019, 04:40 PM

Quote:

Originally Posted by Dargo

Looks like you are doing a job that will last forever. SS coil around the brake cable.

Yep! The nicopp lines won't rust either. SS spring/coil is stone guarding and used in automotive. That protects and gives it strength pretty well. SS hardware. So no rusting issues. No corrosion inside the brake lines. Also the line nuts are SS. The brake hose blocks are brass. Will out last the trailer by far. Do it right the first time and you'll never have to touch it again.

Earl

Dargo · 08-21-2019, 05:30 PM

Quote:

Originally Posted by Mopar_Earl

Yep! The nicopp lines won't rust either. SS spring/coil is stone guarding and used in automotive. That protects and gives it strength pretty well. SS hardware. So no rusting issues. No corrosion inside the brake lines. Also the line nuts are SS. The brake hose blocks are brass. Will out last the trailer by far. Do it right the first time and you'll never have to touch it again.

Earl

Sir, I like your style.

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