Sorry to address this here, but I couldn't find your email address.

On your website, you mentioned taking .610" off the top boss to convert a drum spindle to a disc... How straight and accurate does this have to be? Is it something that could be done by hand, or should I take it to a machinist?

I thought I seen somewhere that someone used a hacksaw, but I just wanted to make sure...

Thanks!
Aaron

It needs to be very accurate to mount the caliper bracket in proper alignment and keep the caliper square to the rotor.

Ditto Joe.....

I would say it really should be machined.
I did have a friend who hacksawed it then finish ground it flat. You can get it machined pretty cheap.
David

i would think that IF you were careful, you could cut it with a hacksaw or the ever dependable sawzall. the caliper floats on the guide pins, so alignment wouldn't seem to be super critical.

It took four different thickness shims to put my calipers on my car so mock everything up like Joe said so that the caliper is wedged tight, parallel against the rotor and go from there.

AND measure close!!

BUT mine is a one-off full custom deal, too...

pdq67

I would say that it is very critical that they are straight.

If you put a straight edge on both studs it should be in 90 degrees to the spindle axle. If not, the brakepads will not be parallell to the disc and you would get warping in the caliper and the bracket. Eventually you would get uneven wear on the pads and probably cracks in the bracket if the missalignment is to severe.

Then it doesn't matter how you do it, just get it done correct (straight that is)

Jan

I chucked my old drum spindles up on the Brideport and used a flycutter. I wouldn't do it any other way.

I agree there's no substitute for the precision of a machine and precise measurements. If someone has the resources (a shop they know or can make an appointment with), it's definitely worth the few bucks to have the upper boss milled perfectly level (square) with the bottom boss.

I used a hack saw. Someone mentioned Saws-All. You have to be one lucky SOB and go as slow as molasses in January to get the cut straight. If you go that route, leave yourself a sixteenth or eighth of an inch and then file or grind down the last bit. Cutting with a hacksaw or Saws-All could very easily start to stray from the intended line and ruin things. But that's what JB Weld is for.
;)

Thanks everyone for the insight. I'll take them to a machine shop.

Matt, what exactly is a Bridgeport and a flycutter?

Thanks again!

Bridgeport is a brand of CNC milling machine and fly cutter is the tool he would use to machine it down.

Wow.... Now let's see... Who to trust??? Any recommendations? Volunteer's? I'll throw in a 12 pack of your favorite beverage....