Brake calliper mounting holes damaged

[Firecatdude]

So as some of you may remember, I posted about bending my track shaft. I had to wait for parts to come in and I was out of town for a bit, so I finally just got to changing the shaft today. I have found that the holes the bolts pass through to bolt into the calliper housing are egg out a little bit with a slight ridge from the shaft being forced upwards from the hit. I filed down the little ridges flat left by the bolts and plan to use some Loctite epoxy to make the holes round again. But my main concern is that the aluminum near one of the holes is bulged a bit. How critical is it for everything is be perfect? Is a little variation in the way the calliper housing sits against the tunnel ok? Or how it sits height wise in relation to the holes! How much is too much? I tired to attach pictures but it said they were too big.

Thanks.

 

[MrSled]

So as some of you may remember, I posted about bending my track shaft. I had to wait for parts to come in and I was out of town for a bit, so I finally just got to changing the shaft today. I have found that the holes the bolts pass through to bolt into the calliper housing are egg out a little bit with a slight ridge from the shaft being forced upwards from the hit. I filed down the little ridges flat left by the bolts and plan to use some Loctite epoxy to make the holes round again. But my main concern is that the aluminum near one of the holes is bulged a bit. How critical is it for everything is be perfect? Is a little variation in the way the calliper housing sits against the tunnel ok? Or how it sits height wise in relation to the holes! How much is too much? I tired to attach pictures but it said they were too big.

Thanks.

reduce the pic to 1024x768 and it will post.

 

[Fords4life]

Can you just hammer and dolly the tunnel flat again? These sleds are far from perfect new, just keep that in mind.

 

[Firecatdude]

Can you just hammer and dolly the tunnel flat again? These sleds are far from perfect new, just keep that in mind.

I did try that. It’s hard to tell but I think that might of made a small crack in the tunnel now. I’m loosing my mind

 

[Firecatdude]

Here are some pictures after resizing. Thanks Mr. Sled for the tip.

You can see in the last pic where the brake calliper was originally and how it slid up after the hit on my track shaft. Other two are taken from inside tunnel. Do you think some epoxy to fill in the top of the holes would be sufficient?

 

[1nc 2000]

This might help.
I have not tried it.

 

[Firecatdude]

That’s interesting. Has anyone on here tried it!

 

[Turboflash]

Here are some pictures after resizing. Thanks Mr. Sled for the tip.

You can see in the last pic where the brake calliper was originally and how it slid up after the hit on my track shaft. Other two are taken from inside tunnel. Do you think some epoxy to fill in the top of the holes would be sufficient?

How loose were the 3 bolts that hold caliper assy on?! There's a large round boss on back side of caliper that fits precisely in a hole in tunnel to keep it aligned. That caliper assy will not move if the bolts are tight.

 

[ksiesel]

That’s interesting. Has anyone on here tried it!

I installed one last spring. I did it for the bearing durability improvement, not for tunnel bolt hole damage. I currently only have around 500 miles on it and it seems to be working well - no complaints. When I installed it, I also installed a new track shaft and new lower bearing in the chaincase.

 

[Firecatdude]

How loose were the 3 bolts that hold caliper assy on?! There's a large round boss on back side of caliper that fits precisely in a hole in tunnel to keep it aligned. That caliper assy will not move if the bolts are tight.

Bolts seemed tight. Never taken apart since factory assembly. The hole that the calliper sits in looks slightly bent inward or outward ( not by sled right now to confirm which way) at the top and bottom when looking at it edge of it, but doesn’t look oblong like the bolt holes. I will have to double check when I get home.

 

[Sevey]

That’s interesting. Has anyone on here tried it!

I am on my first season with it. I like the concept but its too early to celebrate. Based on other things I have tried, i am optimistic this may be my last drive shaft replacement. It also beefs up the mounting area of the drive shaft and seems to support the tunnel side wall really well. Can only be a good thing. Call Ron to speak with him. He's a good guy and has done some big testing.
MS

 

[74Nitro]

How loose were the 3 bolts that hold caliper assy on?! There's a large round boss on back side of caliper that fits precisely in a hole in tunnel to keep it aligned. That caliper assy will not move if the bolts are tight.

You'd be surprised lol. My buddy had a harder hit than that and the bolts were tight. His holes ended up in worse condition that this guy.

 

[Firecatdude]

I am on my first season with it. I like the concept but its too early to celebrate. Based on other things I have tried, i am optimistic this may be my last drive shaft replacement. It also beefs up the mounting area of the drive shaft and seems to support the tunnel side wall really well. Can only be a good thing. Call Ron to speak with him. He's a good guy and has done some big testing.
MS

Thanks for the info. How close is that plate to your track?

 

[Firecatdude]

You'd be surprised lol. My buddy had a harder hit than that and the bolts were tight. His holes ended up in worse condition that this guy.

What did he do to repair his holes? New tunnel? Weld? Rivet a plate on?

 

[74Nitro]

What did he do to repair his holes? New tunnel? Weld? Rivet a plate on?

That was a while ago, I can't remember for sure. I think we made a plate for the two that were easiest to get to, and left the other.
But again, can't recall for sure.