DIY Big Brakes

Shank

TJ Addict
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NE Ohio
Curious if anyone has done this here.

https://www.cherokeeforum.com/f67/17-diy-big-brake-kit-xj-mj-tj-yj-Dana 30-44-a-222937/
https://www.cherokeeforum.com/f67/15-diy-big-brake-kit-xj-mj-tj-yj-Dana 30-Dana 44-227121/
http://jeepm62superchargerkit.blogspot.com/p/blog-page.html
https://www.rme4x4.com/threads/better-brakes-for-the-lj.116389/

Above are links to the most useful links to this as well as an attached pdf. Some info is a little repetitive but there is plenty of good info.


My LJ is mostly stock except OME 2-2.5" springs, 33" tires on 17" JK wheels. The braking performance certainly leaves a lot to be desired. While I could order a Vanco or similar, it seems saving $1000 or more would be worth the slight hassle.

Any thoughts?
 

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  • XJ Brake Upgrade DIY - Joe Collins .pdf
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I've looked into it quite a bit. I always shy away from it because I don't want to get into redesigning a decent steering and trackbar set-up. The Vanco/Black Magic kits comes with new knuckles that allow you to keep the factory steering and trackbar relationship.

So, yes, you might save some coin on the purchase price, but you'll MORE than make up for it, trying to figure out the steering and tracbar relationships.
 
I've looked into it quite a bit. I always shy away from it because I don't want to get into redesigning a decent steering and trackbar set-up. The Vanco/Black Magic kits comes with new knuckles that allow you to keep the factory steering and trackbar relationship.

So, yes, you might save some coin on the purchase price, but you'll MORE than make up for it, trying to figure out the steering and tracbar relationships.

I think you're thinking of the WJ setup that is a bit of a mess. This is far more simple (uses older XJ/YJ knuckle that is bolt on).
 
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Here are some photos from the Black Magic Big Brake kit plus one very ugly photo of my TJ's original single-piston caliper lol. It's a great kit that is fun to install.

Calipers-old-front.jpg


Inserting-brake-clips.jpg


Knuckles-primered.jpg


New-Empty-Caliper.jpg


New-Knuckle-unpainted.jpg


Newly-installed-Brakes-from.jpg


New-Mounted-Caliper-Bleed-F.jpg


Torqueing-caliper-bolts.jpg


Unmounted-New-Caliper-With-.jpg


Bleeding-3.jpg


Caliper-new-backside.jpg


Inserting-brake-clips.jpg


Pads-&-Instructions.jpg
 

Certainly looks like a high quality kit. Definitely has to be a huge upgrade over stock.
 
I think you're thinking of the WJ setup that is a bit of a mess. This is far more simple (uses older XJ/YJ knuckle that is bolt on).

It is mostly bolt on except for the parts that aren't. That is the same knuckle that a company used to "copy" our stuff. Those knuckles have a big problem for lots of folks who actually take their rig wheeling. Due to the fixed upper ball joint and the need to set the distance between the two tapers by tightening the lower tapered nut onto the lower balljoint stud, that enlarged the hole by more than a small amount.

If you ever look at the parts in a set of Spicer Ball joints, you may have noticed the gold threaded adjuster. That gets threaded into the bottom hole of the knuckle and torqued down onto the tapered pin. That makes the hole very large and really weakens that part of the knuckle which is also the part that carries the weight of the rig. If you work it hard offroad, you can easily rip that out and turn a good day into a very bad day. The best we've ever been able to do is just glob enough weld in there to try and stick the pin to the hole enough to get them back to camp and on the trailer.

I'm more than capable of copying that method and even duplicating that exact knuckle. It isn't strong enough for me to sell it to anyone in good conscience.

That said, if you head down that road, post up, I've done lots of custom brakes and brake conversions and will be more than pleased to provide you with all the technical support you need to pull it off. It is always good to see folks figure stuff out.
 
It is mostly bolt on except for the parts that aren't. That is the same knuckle that a company used to "copy" our stuff. Those knuckles have a big problem for lots of folks who actually take their rig wheeling. Due to the fixed upper ball joint and the need to set the distance between the two tapers by tightening the lower tapered nut onto the lower balljoint stud, that enlarged the hole by more than a small amount.

If you ever look at the parts in a set of Spicer Ball joints, you may have noticed the gold threaded adjuster. That gets threaded into the bottom hole of the knuckle and torqued down onto the tapered pin. That makes the hole very large and really weakens that part of the knuckle which is also the part that carries the weight of the rig. If you work it hard offroad, you can easily rip that out and turn a good day into a very bad day. The best we've ever been able to do is just glob enough weld in there to try and stick the pin to the hole enough to get them back to camp and on the trailer.

I'm more than capable of copying that method and even duplicating that exact knuckle. It isn't strong enough for me to sell it to anyone in good conscience.

That said, if you head down that road, post up, I've done lots of custom brakes and brake conversions and will be more than pleased to provide you with all the technical support you need to pull it off. It is always good to see folks figure stuff out.

I appreciate the response and that makes quite a bit of sense. For my purpose I would imagine it would be plenty fine but it at least has me thinking,
 
Getting the track bar in the correct position for WJ knuckles requires a fair amount of work. A lot of the inspiration for this project was taken from Blaine’s “justaddrocks” photo collection.
01540FD0-3490-484F-BF2F-803702C33A7A.jpeg
 
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Getting the track bar in the correct position for WJ knuckles requires a fair amount of work. A lot of the inspiration for this project was taken from Blaine’s “justaddrocks” photo collection.
View attachment 402340

It is a stupid amount of work to get it right. The only problem you have is those offset tie rod ends. They will let you down when you least need them to. The offset will bend your link under high force and ruin your day. If I had my way, they would just outlaw those damn things.
 
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If anyone is interested, I have a set of the early XJ knuckles.

I was planning on going down that road, but I've decided to save my pennies and go with the Black Magic Big Brake kit.
 
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If anyone is interested, I have a set of the early XJ knuckles.

I was planning on going down that road, but I've decided to save my pennies and go with the Black Magic Big Brake kit.

Depending on price I would be. I have a few sets in a local junk yard it seems, waiting for pricing.