Ok, after much delay, I finally did a thing with the ebrake.
When I had the tranny and tcase out I picked up a smaller caliper because I didn't like how the big one hung out off the back.
Made a bracket for the little one and then found I'd miscalculated and it would just barely touch the floor pan. So I put it all away for a year.
Could have rotated the output flange one hole and had it work, but I'd lost enthusiasm for it.
Crawled underneath last week with the bigger caliper and figured a few things out.
Here's the two calipers together, both are wilwood, but you can probably see why I'd rather use the big one.
Bracket I'd made for the small one last year. It worked I guess.
Don't mind the booger welds, my welding helmet battery died, so this was mostly blind welding.
So, enter the new CAD templates ( Cardboard assisted design)
Thankfully there's a nice little plasma at work, because this would suck to cut out with a zip.
Which led to this...
Wasn't sure with that top cap if I'd be able to get the output flange with rotor on, but because the rotor is loose until the drive shaft is bolted up, there's enough play in it to get it slid on.
I'll definitely remember to goop the splines before I put it together, all that oil you see is from that. I knew I'd be in there again and didn't want to fight the goop. Didn't think it'd take a year, but here we are.
It'd be a cleaner looking installation if the caliper could face the other way, but you'd need a rotor that was quite a bit larger diameter. This one is 9.5", and I think it would have to be more like 11 or 12" to clear the body of the tcase.
I could have made a larger one, but having the rotor not be lower than the tcase seemed like a good idea.
Makes it easier to mess with the ebrake cable this way, it'd be a pain in the ass if it was up on top of the case, but it does make the bracket more awkward.
Think it'll work tho. I'll park on something steep as hell to test. Has to be better than the s***ty old stock 40 tcase brake.
Now to see if I can get an ebrake cable to work out of all this s***.
This truck has the dash pull, so we'll see if I use it or not.