Electric Brakes

[smokeonthewater]

Re: Electric Brakes

since ur lookin into engine mods check out powerstrokenation.com

 

[bgc]

Re: Electric Brakes

Kevin, thanks for that! It's exactly what I was looking for! I'm going to get a set of Dexter Nev-R-Adjust 3500lb brakes for both axles!



Yeah. I know about the 6.0L 'problems'

Just bought this truck after an EXTENSIVE search for info on the 6.0L engine. It's only got 26,000 miles on it and I bought it from the original owner. It didn't look like he ever drove it or even sat in the seats! I plan to watch (Scanguage II) it pretty closely and probably do a newer updated oil cooler and either a "Bullet-Proof" EGR cooler (or a delete) ......NO HP increase though...... so I suspect I won't need to do the head gaskets/studs..

I went with the BulletProofDiesel EGR cooler in. That, a good pH+ and pH- flush, and OAT coolant put an end to the clogged coolers. Using REVX and Rotella T6 oil extended the life of the injectors and dramatically reduced stiction.

 

[HT32BSX115]

Re: Electric Brakes

I went with the BulletProofDiesel EGR cooler in. That, a good pH+ and pH- flush, and OAT coolant put an end to the clogged coolers. Using REVX and Rotella T6 oil extended the life of the injectors and dramatically reduced stiction.

The 6.0L engine was in Ford trucks from 2003-2007 (E-series until about 2010 or so) ........There is SO much info on what goes wrong with them, why it happens, how to fix them, how to prevent the problems and make them reliable...... that I thought one would be right for me!

I won't have any problem doing the required mods.

 

[bgc]

Re: Electric Brakes

Yes there is plenty of info out there about them.....just gets expensive, quick. (Kinda like boatin)

 

[HT32BSX115]

Re: Electric Brakes

Ok Y'all,


Got my new Dexter Nev-R-Adjust brakes! 4 drums and 4 brake units for approx $100 per wheel! Bought them from a trailparts place in Ca that uses EBAY and the above price included shipping (no tax)!

The only problem I have is TrailRite didn't put brakes on both axles and (of course) didn't bother to weld a brake flange on the axles without brakes!

So, I have to make up a "jig" and weld a couple of flanges on to the axle.

I bought the flanges from ebay also and will just make up the jig using one of my old hubs.

Then I'll GTAW (TIG) weld the new flanges to the spindles!

These electric brakes appear to be at least as "good" as what I removed.

The magnets are epoxy sealed.

I don't think fresh water will hurt them at all. (I don't do salt) And around the NW (Puget Sound) some of the launch areas have slingers so I wouldn't have to get the trailer wet anyway!! Public Sling Launch

terribly accident! YACHT FALLS from CRANE into water while being carried into ship. - YouTube :facepalm: well..........maybe not!!!

 

[alldodge]

Re: Electric Brakes

Ok Y'all,


Got my new Dexter Nev-R-Adjust brakes! 4 drums and 4 brake units for approx $100 per wheel! Bought them from a trailparts place in Ca that uses EBAY and the above price included shipping (no tax)!

The only problem I have is TrailRite didn't put brakes on both axles and (of course) didn't bother to weld a brake flange on the axles without brakes!

So, I have to make up a "jig" and weld a couple of flanges on to the axle.

I bought the flanges from ebay also and will just make up the jig using one of my old hubs.

Then I'll GTAW (TIG) weld the new flanges to the spindles!

These electric brakes appear to be at least as "good" as what I removed.

The magnets are epoxy sealed.

I don't think fresh water will hurt them at all. (I don't do salt) And around the NW (Puget Sound) some of the launch areas have slingers so I wouldn't have to get the trailer wet anyway!! Public Sling Launch

terribly accident! YACHT FALLS from CRANE into water while being carried into ship. - YouTube :facepalm: well..........maybe not!!!

You take all the fun out of it using a jig. I installed flanges on my third axle with a square. Also have to admit I'm not that good at welding but like my MIG over the stick

Saw the boat fall off video a few years ago, was pretty bad, hope they had insurance

 

[bruceb58]

Re: Electric Brakes

I had the same issue but I decided to get another axle. I am also a very good welder with both MIG and TIG. I got talked out of doing it because of the need for an accurate jig.

 

[smokeonthewater]

Re: Electric Brakes

a few 90 degree magnets and a tape measure were all the jig I needed.... not rocket surgery.... a few thousandths doesn't matter

 

[HT32BSX115]

Re: Electric Brakes

a few 90 degree magnets and a tape measure were all the jig I needed.... not rocket surgery.... a few thousandths doesn't matter

True. but it is nice to do it "right"!

I am using one of the old hubs to make the jig. I took a piece of 1/4" steel and cut a hole in it (with my handy-dandy HF plasma cutter)

I bolted it to the back of the hub.

Then bolt another plate to an existing flange (on the axle that has flanges) and weld that plate (using gussets) to the one that is bolted to the back of the hub.

I'll use that lash-up to bolt to the new flanges. So if the flanges already on the current axle are "square" then the ones I weld on will be too!


I was just going to buy myself another axle but I have to justify having that Miller Synchrowave 180 and the Harbor Freight plasma cutter!!

 

[bruceb58]

Re: Electric Brakes

I have a ThermalArc inverter TIG and a Hypertherm Plasma and I also understand how you think. I was close to doing it myself as well. the fact that I was putting on disk brakes made me wanting to have it perfect. New axle was $250 and I sold the old one for $75.

Maybe doesn't need to be perfect for drum brakes.

 

[HT32BSX115]

Re: Electric Brakes

I have a ThermalArc inverter TIG and a Hypertherm Plasma and I also understand how you think. I was close to doing it myself as well. the fact that I was putting on disk brakes made me wanting to have it perfect. New axle was $250 and I sold the old one for $75.

Maybe doesn't need to be perfect for drum brakes.

I think you're right. (Although I think I will get it it "perfect")

My next boat will have E/H Kodiac Disc brakes on it though (all three axles!!)

 

[bruceb58]

Re: Electric Brakes

I think you're right. (Although I think I will get it it "perfect")

My next boat will have E/H Kodiac Disc brakes on it though (all three axles!!)

that is what I have. they work great. 2 axles.

 

[smokeonthewater]

Re: Electric Brakes

this jig doesn't sound very rigid... make sure you do a few tacks n measure and a few more tacks n measure again before you burn it in.

 

[HT32BSX115]

Re: Electric Brakes

this jig doesn't sound very rigid... make sure you do a few tacks n measure and a few more tacks n measure again before you burn it in.

Actually, using 1/4" steel, it's pretty rigid. I ended up using one of the old brake backing plates........

I drilled the plate I made for the back of the hub out of 1/4 also and drilled 5 holes (1 for each lug bolt).

I then used the existing lug bolts and bolted it to the back of the hub.

I took 2 pieces of rectangular 1/4" scrap and welded each to the hub-plate and the old brake backing plate approx opposite to each other (while the backing plate was bolted to the existing flange)

So assuming the existing flange is correct, the new flanges will be in exactly the same place.....................

 

[HT32BSX115]

Re: Electric Brakes

All welded in!

Tomorrow, I'll re-install the axles, brakes, hub/drums and wire it all up!

Can't wait to try my FOMOCO brake controller!

 

[bruceb58]

Re: Electric Brakes

All welded in!

Tomorrow, I'll re-install the axles, brakes, hub/drums and wire it all up!

Can't wait to try my FOMOCO brake controller!

OK, Let's see pictures!

I bet the built in controller works better than the aftermarket ones. It probably knows how hard you are pressing on the brake pedal instead of relying on the inertia sensor.

 

[HT32BSX115]

Re: Electric Brakes

OK, Let's see pictures!

I bet the built in controller works better than the aftermarket ones. It probably knows how hard you are pressing on the brake pedal instead of relying on the inertia sensor.

You know, it might. I don't know. I rather like how the truck is already equipped and wired for trailer brakes.
Here's a couple of pictures


After I bolted the piece of scrap to the inside of the hub and mounted it on the flanged axle, I used some other pieces of scrap to "eyeball" measure how I would mount them.

With the older brake backing plate as a guide bolted to the existing flanges and the hub on the spindle, I welded the scrap plates to the hub plate and the backing plate.

Once the "jig" was together, I removed it from the existing flange, bolted the new flanges to jig-backing-plate and and slid the entire mess on the other axle. I then tack welded the flange in 4 places on each side before completely welding it in place.

Continues in the next message....(max 6 images allowed)

 

[HT32BSX115]

Re: Electric Brakes

Miller Syncrowave 180SD I used

Pretty much ready now to put the axles back on and wire them up.

here's the new Tie-down Engr coupler to replace the surge-brake coupler.

 

[bruceb58]

Re: Electric Brakes

That looks good.

I assume you felt that the original brake backing plate was rigid enough not too warp at all when you did your welds to it?

 

[HT32BSX115]

Re: Electric Brakes

That looks good.

I assume you felt that the original brake backing plate was rigid enough not too warp at all when you did your welds to it?

Welding the gusset plates to the backing plate at the periphery with fairly short welds didn't warp the original backing plate at all...

I also "tacked" new flange in 4 places on both sides before removing the backing-plate jig........... even though, after I finished, I still had a little warp in the flange..... a gentle tap with a peen hammer brought it right in!

Even if the backing plate is not perfectly aligned, the brake shoes self-align to a certain degree. They're capable of a fair amount of movement once they actuate.


The (hydraulic-drum) brakes on that axle worked well for more than 20 years. I just wanted brakes on all four axles.....and I really disliked the way it towed with the surge brakes....

My second choice was going to be new Dexter 3500lb straight axles which would raise the trailer approx 2.5" ........... (I may still do that in the future if I keep the boat!!)

I've always thought the trailer was a little lower to the ground than it should be......The Bravo III is a little longer than the Cobra so I can't put the drive all the way down on the trailer. I just deal with it though