87350IROC

iTrader: (2)

I have had a few requests to adapt my Dana 44 bracket for the 9-bolt. I decided to make this one 2pc for a few reasons.

Reduced thickness - 9-bolt has a lower offset than my D44

Cost of manufacture - components can be water jetted

Because the bracket is thinner, the inner caliper bracket needs to be made from steel, 1/4" thick. The outer bracket is 5/8" thick and can bee made from steel or aluminum. The full steel bracket weighs about 3lbs with shown hardware.

A 1.5mm thick shim needs to be used between the bracket and caliper. A very small shim (0.015") between the outer bracket and e-brake backing plate would be ideal, but probably not necessary. The shims are required in order for the rest of the bracket to use normal stock sizes to reduce cost.

Another option is to make both pieces out of steel and weld the two together. That would eliminate the need for the rear nuts and allow you to run shorter bolts. In this case the holes would need to be drilled and tapped to 1/2"-20 instead of the 0.52" thru holes. Just need to be careful not to warp the bracket during welding.

Also, the holes in the CTS-V backing plate are 3 holes spaced 120 degrees apart. Due to the packaging of the 9 bolt flange, two of those 3 holes had to be moved. So you will have to drill two additional holes in the CTS-V backing plate and enlarge the center hole to accommodate the axle retention plate.

I also wanted to add that I need to verify a few measurements before I am willing to release all the dimensions. Stay tuned.







And for reference, here is what my complete Dana 44 setup looks like. And showing the OEM CTS-V e-brake backing plate. My bracket is one piece aluminum.

87350IROC

iTrader: (2)

And a quick drawing.

Copchaser

iTrader: (2)

Very nice and detailed work here my friend. Please keep us updated as time permits.

Are the same e-brake parts you listed in your other thread the same ones I'm going to need to begin looking for?

87350IROC

iTrader: (2)

That list needs a little bit of an update. I over bought on some of the hardware and under bought on the e-brake shoes. I will post an updated list tonight.

BlackenedBird

iTrader: (5)

Is this something that you intend to make & sell? Or just drawings for us to make ourselves?

87350IROC

iTrader: (2)

I would not mind selling these but I do not have access to an efficient way to make them. So for now, its just for you guys to make.

87350IROC

iTrader: (2)

Here are the part numbers:

Part Numbers:

Front
25912477 - caliper
25912967 - caliper
25940447 - pads
25940448 - x2 caliper pin kit
1771105 - x2 rotor

Rear
25911138 - caliper
25911233 - caliper
89047744 - pads
1771051 - x2 rotor
???????? - x2 caliper pin kit (don't remember if these came with the calipers)

E-brake
25851190 - backing plate
25851205 - backing plate
25693149 - cable bracket
25693150 - cable bracket
25814678 - x2, shoe kit
25867413 - x2, shoe lever arm
25867414 - x2, shoe leveler
20823795 - cable
20823866 - cable equalizer
18K2087 - spring and hardware kit

BlackenedBird

iTrader: (5)

Why would you need Front & Rear brakes to do the 9-bolt conversion? And what is the minimum diameter wheel you would need to do this conversion?

87350IROC

iTrader: (2)

Minimum wheel diameter is 18". I have personally slide a BMW M Parallel 18" knockoff over these brakes. I cannot guarantee every 18" out there will clear. The other consideration is caliper to spoke clearance. These require pretty good clearance in that area. I'll see about some measurements when I get my diff back.

BlackenedBird

iTrader: (5)

That rules them out for me. Got almost $2500, including tires, in my 17"s. $1100 alone in just the rear 2 wheels.

paul_huryk

I'm not sure if they will fit the Brembos (if they are larger than 14" rotors), but my CTW Motorsports wheels easily fit over Baer's largest 3rd gen kit, the Extreme Plus with 14" rotors and 6 piston calipers. Would need to check clearance with an actual fit - check this out:

87350IROC

iTrader: (2)

I forgot about that. The V rotors are nearly 14.4". I doubt they will fit, but I'll post up a measurement once I get my diff back.

TEDSgrad

iTrader: (4)

Does this mean that you gave up on the FSL Wilwood rear set-up?
I"ll be going ahead with that next Spring. Any chance you could do the bracket specs?

87350IROC

iTrader: (2)

That is correct. I ended up with the 19" wheels and realized the 13" Wilwoods were just not going to fill the wheel like I wanted. Its a stupid reason to "upgrade" but in this case its the truth.

The other issue with the Wilwoods is figuring out an e-brake. I have looked at the small mechanical calipers used as an e-brake, but it seems like most people have not had a lot of luck with them.

I should be able to work something up with the Wilwoods. I have 100 projects going on right now though, so progress will be slow.

John

87350IROC

iTrader: (2)

Hey, what rotor size are you planning on? Do you have any particular rotor in mind? I'm thinking 12"x0.81" would be great unless you want to go for more bling in which case I think a 13"x0.81" would be good.

TEDSgrad

iTrader: (4)

4 pot 12" is fine for rear.
I used 2 PC wilwood hat with Coleman curved vane 13" in front

87350IROC

iTrader: (2)

Cool. I assume you plan to use the FSL in the back with smaller pistons? That will be a really nice setup. Do you want to use a 2pc rotor in the rear as well?

Hmm, I just realized doing the e-brake in the rear won't work the same as this setup, unless we use the CTS-V rotor. Which would obviously be strange due to its large size. I think maybe something like the LS1 rear rotor + ebrake setup might be good for you with the FSL caliper instead of the LS1 caliper.

87350IROC

iTrader: (2)

Alright folks, I did some more tuning. We are getting close. I have the 2-D dimension down pat now. Its just a matter of figuring out how thick the caliper spacer should be. I am having some minor issues with that measurement on my Dana 44 setup, so I am not able to currently trust those measurements. Either way, due to production tolerances that may require custom shimming for the end user to figure out. I am finding despite my best efforts to keep everything square, my setup on my Dana requires a different shim thickness on the top bolt than the bottom. The difference is small (~0.01), but worth getting correct. Obviously the axle flange is not perfectly perpendicular to the caliper bracket.

Other than everything else talked about here, it looks like the one nut on the back will need to be ground slightly. Or you could grind the axle housing flange. Notice the overlap between the flange (white parallelogram) and the nut on the right. Also the gap between the flange (white parallelogram) and the e-brake cable bracket studs (holes on left) is very small. So you might have some grinding to do on the e-brake cable bracket as well.

I should be ready to release the files within the next few days. I am not going to post them on here for liability. You guys can PM me and I will send them out.

TEDSgrad

iTrader: (4)

Would like 2 PC rotor in order to match, slotted only not drilled. When you say LS1do you mean style, or direct replacement? I think 2 PC gives many fitment options.

87350IROC

iTrader: (2)

The problem is the e-brake, as I just realized. You did want an e-brake right?

The sytles I have been working with have the internal drum style e-brake. This means the hat needs to have a friction surface inside of it. I don't believe many off the shelf 2pc kits have this surface. What did you want to do about the e-brake?

87350IROC

iTrader: (2)

I created a new thread for the FSL 9-bolt setup. Better to keep them separated before I get confused.

https://www.thirdgen.org/forums/brak...ml#post5374960

TEDSgrad

iTrader: (4)

I see now. Yes, want e-brake. I guess I could get the rotors slotted to cosmetically match. This will work. I'll call around, tomorrow.
Thank you!

TC3G89

This is awesome stuff.

Mike92Firebird

iTrader: (3)

So I was discussing rear braking options with Scott after buying my front C6 set-up, the topic of these came up:



I was given this picture before it is shown on the website. Just wanting to give everyone a sneak peek. Scott had this to say, "These brackets mount 2008-2014 cts-v brakes with or without parking brake to 9 bolts or 10 bolts"

This is freaking awesome! A real solution for anyone wanting to upgrade their rear brakes.

The rest of the details can be found here: http://www.bigbrakeupgrade.com/Rear_Brake_Kits.html