Bespoke Front and Rear Big Brake Kit(Bigger than big) with Electronic Parking Brake

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(2/2) Second OCD side quest... I ABSOLUTELY HATE "one size fits only a few" wiring harnesses. I've always redid my own specific length harnesses for my Baja Design lights. I previously mentioned the Wilwood EPB module should be mounted under the front seats, but seems like the Wilwood harness doesn't really allow for that location as wiring doesn't split off in correct sections. Wilwood states it should be behind the dash, but me being me, I decided to cut up the original harness and redo some stuff. Currently WIP

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Dang, tough crowd. More comments about a font than the product itself this last page. Anyways, already been noted and planned to update.
Well, look at it this way, we're only ripping on the part we don't like. If the worst we can find wrong with it is the font, you must be doing something right! 😜

Edit: also, 100% with you on solutions that expect you to just bundle up an overly long harness into coils. Not a fan.
 
Dang, tough crowd. More comments about a font than the product itself this last page. Anyways, already been noted and planned to update.
I think everyone is speechless when it comes to your product. Seeing little glimpses of your R&D process is super interesting! I would LOVE to run some brakes like these.
 
(1/2) Now back to topic, my OCD took me on a side quest... This bracket replaces the factory parking brake lever. Houses the Wilwood EPB controller module, switch, and my Switch Pros SP9100 control panel. Made from stainless 304.
Seems like a good re-use of that space, since the hand brake would be gone. Clever.
 
Well, look at it this way, we're only ripping on the part we don't like. If the worst we can find wrong with it is the font, you must be doing something right! 😜
Well said
 
Short update. Got all the wiring done ,cut to length to utilize the center console bracket I made for myself, and FINALLY got everything in and running. Taking the next few days to rack in some miles for initial bed in process then final bed in doing a sequence of back to back to back stops.

Forgot to take a pic of the wiring after I finished, but this shows just before I finished sleeving everything. Sooo much simpler and cleaner...
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Comparing original wiring harness as it came from Wilwood as a "One Size Fits All" to original 80 series parking cable.
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I think I must have cut off at least 35 feet of excess wires if we joined all the individual wires together! All joints soldered.


Couple quick snaps while out for groceries(bad quality from my phone in poor lighting).
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What a massive amount of effort to date. Looking forward to seeing product available sometime soon. Once you have sorted out the 80 series products please review what you might be able to offer us 100 series folks. My current go-faster mods require me to circle back to also require me upgrading my go-slower mods
 
I'll post this video here first...

EPB in full effect. 3 ton Toyota on 38's and a steep hill vs 2400lb clamping force of each EPB. :cool:




Larger tires create more leverage the brakes would need to counteract. This includes the parking brake. Inner drum diameter on the 80 is roughly 9"(4.5" radius), moving this out to a 14.25" rotor where centerline of EPB pad is sitting at roughly 7" radius, the effective increase is at 155% of original if we were to only apply the same exact clamping force. BUT... EPB can create over 2400lbs of clamping force. This goes without saying though, always angle your front wheels correctly when parking on a hill.
 
@reklund5 and I need to make a trip out to see you. I first need to know if these bad boys are going to play nice with my Hutchinson RockMonster wheels before I get too fixated.
Could always move up to an 18" beadlock ;) Few years ago I said that more and more trucks are coming with 18's, likely to allow for bigger brakes since they're becoming heavier and heavier and that the aftermarket would follow suite. Now we see so many larger diameter tires(>37") for 18" rim diameter.

Just hit about 120 miles of city driving, so going to be doing the last part of the bedding in process for the pads tomorrow. Is @Outsane still offering hotdogs? 😁


Some added tidbits:

With the increase in rear rotor torque I was able to pick a bit more aggressive pad up front to complement the brake bias. So after roughly 3 years this is the first set of brake pads, still a significant amount of life left. New is 17mm.
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I know what you're thinking. Land cruiser math means save on replacing brake pads yearly by buying this big brake system 🤣

Honestly was surprised there was this much left considering how aggressive I've tried to be with the brakes. YMMV But that does bring me to adjusting the pushrod length. Over the years I was slowly getting more pedal travel, and thought it was the pads wearing since these have significantly more volume than the stock 80 pads so later in it's life the pistons would require more travel to engage the rotor.

For reference, here's a comparison between OE front pad - bottom, to Superlite 4R(7420) - middle, to Aero 4(6617) - top
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This got me to looking into my master cylinder pushrod adjustment by the brake pedal clevis, and low and behold the locking nut had completely loosened. Freely spinning with a slight spin from the finger. Adjusted it a bit(safer to not overadjust), prob should have done alignment, but it gets me by for now. Definitely better response now like I used to have.
 
I'll post this video here first...

EPB in full effect. 3 ton Toyota on 38's and a steep hill vs 2400lb clamping force of each EPB. :cool:



The real test: Put it in gear and rev it to 1500 rpm. Does it move? 😉

Could always move up to an 18" beadlock ;) Few years ago I said that more and more trucks are coming with 18's, likely to allow for bigger brakes since they're becoming heavier and heavier and that the aftermarket would follow suite. Now we see so many larger diameter tires(>37") for 18" rim diameter.

One of the reasons I bought 18" rims was for future brakes and that all Ford 150/250/350 Tremors use 18" rims. Super Duty Tremors came with 285/75R18, which is narrower than most 35" tires. Because of that, 285/75R18 tire size will be readily available for years...
 
The real test: Put it in gear and rev it to 1500 rpm. Does it move? 😉



One of the reasons I bought 18" rims was for future brakes and that all Ford 150/250/350 Tremors use 18" rims. Super Duty Tremors came with 285/75R18, which is narrower than most 35" tires. Because of that, 285/75R18 tire size will be readily available for years...
Actually did this a couple days ago, didn't pay attention to how high the revs went, but did take a few good attempts to get it to even budge. I'll try and record something today.

Kind of the same approach I took with 18's, though I'm on a 38" tire. Just more room to fit larger brakes. The front can technically accomodate a 15" rotor. And with the front brakes being 2 piece rotor and caliper being radial mount, all that's needed is the 15" rotor and roughly 1/2" spacer for the caliper. This will likely be my route when the front rotors need replacing, which may be another 2+ years given the current wear rate 😁
 
Actually did this a couple days ago, didn't pay attention to how high the revs went, but did take a few good attempts to get it to even budge. I'll try and record something today.

I mentioned the RPM because it is part of the parking brake inspection in Massachusetts.

Test Requirements:
The parking brake shall be tested by accelerating the motor to approximately 1200 to 1300 RPMs with the vehicle in the lowest forward gear against the brake in the applied position, and shall be found to hold the vehicle...

Somehow my truck passes this test...even with a 6.0L V8 motor. No idea how...

I figured the EPB must be good to at least 1500 rpm...
 
Gearing would make a bit of a difference and so does tire size.

With 4.88 gears and 38's seems to hold until 1400rpm, maybe higher with more gradual throttle input. Stock tires and gearing should hold much higher. Somewhere in between like 35's and 4.56 should still see an improvement in holding power.

 
Gearing would make a bit of a difference and so does tire size.

With 4.88 gears and 38's seems to hold until 1400rpm, maybe higher with more gradual throttle input. Stock tires and gearing should hold much higher. Somewhere in between like 35's and 4.56 should still see an improvement in holding power.


Great video! Thanks for making that.

I think I have more torque at any given engine rpm, assuming you still have 1FZ-FE with the stock A343 transmission.

Example at 1200 rpm:

Your tire/gear combo should be at 9.9 MPH.

Which is actually very close to stock (4.10/31" Tires): 9.7 MPH.

I have 6L90e with a 4.03 1st gear, 4.10s and 35" tires = 7.6 MPH.

Slower = more torque at a given RPM.

Also, I have a 6.0L V8...

1FZ-FE is producing about 217 lb-ft at 1200 rpm

While the L96 will be in 300–325 lb-ft range at 1200 rpm.

This means the EPB will have no hope holding my truck back at 1200-1300 rpm...😟
 
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