Title

Toyota Disk Brake Conversion

Presenter Information

Geoffrey Gibson

Document Type

Oral Presentation

Location

SURC Ballroom B/C/D

Start Date

21-5-2015

End Date

21-5-2015

Keywords

Deflection, Stress Analysis, Thickness

Abstract

A common issue with Toyota pickups from the 1980s is that the factory braking system is not responsive enough for the driver to properly brake during an emergency situation. The cause of the poor response in braking comes from the drum brakes that are on the rear of the vehicle. Aftermarket vendors offered disk brake conversions that change the brakes on the rear axle from drum to disk. The aftermarket brackets that are in the conversion are thick and bulky, adding excess weight to the already heavy pickup. These thick brackets in the conversion do not retain the factory emergency brake which is required to maintain proper functionality. To remedy the issue, a set of brackets were designed around the use of Ford Mustang calipers and Mitsubishi Montero rotors in order to retain the factory emergency brake and to maintain the correct wheel lug pattern. In order to reduce the bulk of the brackets, stress analysis was performed on the bracket design to find the minimum allowable thickness. This was performed over multiple materials to use different thicknesses. Once a thickness was calculated for each material, it was reevaluated to ensure that the brackets would not deflect more than what the tolerance allowed. With brackets designed and built, they will be tested on the test vehicle where the deflection of the bracket will be recorded and compared to the .005” tolerance. The calculations that were performed prove the vehicle will safely stop in the specified distance of 75 ft at 40 mph.

Poster Number

30

Faculty Mentor(s)

Charles Pringle

Department/Program

Engineering Technologies, Safety, & Construction

Additional Mentoring Department

Engineering Technologies, Safety, & Construction

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May 21st, 2:30 PM May 21st, 5:00 PM

Toyota Disk Brake Conversion

SURC Ballroom B/C/D

A common issue with Toyota pickups from the 1980s is that the factory braking system is not responsive enough for the driver to properly brake during an emergency situation. The cause of the poor response in braking comes from the drum brakes that are on the rear of the vehicle. Aftermarket vendors offered disk brake conversions that change the brakes on the rear axle from drum to disk. The aftermarket brackets that are in the conversion are thick and bulky, adding excess weight to the already heavy pickup. These thick brackets in the conversion do not retain the factory emergency brake which is required to maintain proper functionality. To remedy the issue, a set of brackets were designed around the use of Ford Mustang calipers and Mitsubishi Montero rotors in order to retain the factory emergency brake and to maintain the correct wheel lug pattern. In order to reduce the bulk of the brackets, stress analysis was performed on the bracket design to find the minimum allowable thickness. This was performed over multiple materials to use different thicknesses. Once a thickness was calculated for each material, it was reevaluated to ensure that the brackets would not deflect more than what the tolerance allowed. With brackets designed and built, they will be tested on the test vehicle where the deflection of the bracket will be recorded and compared to the .005” tolerance. The calculations that were performed prove the vehicle will safely stop in the specified distance of 75 ft at 40 mph.