need info about welding cast metal

[pjtoledo]

I've a question for the welders out there, can the front caliper brackets be safely welded?

the reason I'm asking is to install 12" front rotors on my 11.25" equipped '05 Ranger.
Background info:
When Ford put the 12" rotors on Sport tracs and later Rangers they redesigned the steering knuckles to move the caliper mount holes out 3/8" to allow the 3/4" larger rotors. the calipers and anchor brackets are the same for both versions. for the 98+ torsion bar Rangers a swap of the steering knuckles is all that's needed for bigger brakes.
unfortunately for us 98+ coil spring guys there are no bolt-on part swaps to do this.
However:
there is a 12" rotor/hub that will fit the 98+ coil spring rangers, but the caliper bracket would need to be moved out 3/8" for it to work.

So, that brings us back to the question of the day:
can the caliper brackets be welded safely to fill the holes and add enough metal to drill new holes 3/8" closer to the bottom?

that is the only modification needed to put the 12" rotors on the 98+ coil spring Rangers. 2001 2wd Sport trac 12" rotors are a direct fit, use the same calipers & pads.

side note, will need bigger wheels to clear bigger brakes.

I'm in northwest Ohio and can travel a couple hours to anybody that wants to try this.


Perry

 

[85_Ranger4x4]

Cast can be welded, it is usually a last ditch effort to save something though.

I doubt a shop would touch it for liability if the caliper came loose/off.

 

[alwaysFlOoReD]

Can you tap the present hole and plug with a NPT pipe plug? Then grind smooth, drill new hole where it needs to be.

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[pjtoledo]

Can you tap the present hole and plug with a NPT pipe plug? Then grind smooth, drill new hole where it needs to be.

Sent from my XT1032 using Tapatalk

I don't think there is enough metal to move the hole, it would be very close to the edge.

 

[Curious Hound]

This is a safety item. My experiences with welded cast.iron have not been great and those were all jobs done by good welders. I would recommend that you find the right parts to do this mod. If welding stresses cause a broken steering knuckle, the results could be disastrous. Your life and the lives of others around you depend on this being done right.

I'm not trying to rain on your parade. But steering and brakes are not things to take lightly.

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[pjtoledo]

I'm kinda thought it would be a long shot, but bigger brakes on 'ol Junior has always been something I wanted to do. I'm fully aware of how things can go wrong, that's why I wanted a welders opinion on this idea.

watching some of the shows on TV, its clear that some brackets get welded. But those are usually plates with bushings welded on, not cast parts.

keep the comments coming, I haven't given up yet.

 

[Doofy]

Ditto to nixing the welding idea. I once welded a broken tie rod to get me 160 miles to a repair shop. I was so nervous, my Ass chewed a hole in the seat. Just not worth taking a chance!

 

[alwaysFlOoReD]

Is there enough meat to mill off some and make an adapter plate?

 

[AllanD]

I'd be inclined to say NO!


I could suggest that making an adapter plate along with offsetting the caliper along the circumference of the rotor which would also require some dust shield trimming... instead...

 

[Shran]

Another NO vote here. I have welded a lot of cast stuff but not anything like this. You would be combining vastly different types of alloys together and the heat alone would likely make it brittle.

 

[97RangerXLT]

Another No vote from me.

What would the cost be to have a local shop machine you a pair of new brackets that are 3/8" longer?

AJ

 

[Blown]

I wouldn't try welded calipers. Most welders wouldn't try to do so.

The best though not inexpensive idea here is new custom machined mounts. aluminum would save weight.

 

[pjtoledo]

the "nays" prevail, there will be no welding.

the cheapest and easiest alternative would be Wilwood radial mount calipers and custom mounting bracket. that would keep the geometry the same. that mounting bracket is basically a piece of square stock with 2 holes one way and 2 holes the other way for the studs.

time to hit the pick-n-pull to see if there is anything close enough that I could just enlarge the holes slightly off center.

 

[AllanD]

I will add a comment that the Relatively rare Saleen Explorers were all recalled so that their larger front brakes and caliper brackets could be removed and replaced with stock components...

 

[ZMan]

Didn't someone make a bracket at one time for this mod? I got the kit for putting 13" Cobra brakes on an I-beam truck 8 or 9 years ago, I know the 12" mod for the newer ones got popular after that.