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5.9 Cummins, NV4500, Hydro-boost, and Disc Brakes

mudguppy

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... Doing two axles of his kit already exceeds the price of the entire truck! ...
oh, and i don't take this as a personal dig or anything, but i don't understand this comparison.

much like the winch discussion, just because the truck is obtained for 'dirt', why should everthing else be procured for a similar discount?

i don't understand this logic.
 

mendo

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oh, and i don't take this as a personal dig or anything, but i don't understand this comparison.

much like the winch discussion, just because the truck is obtained for 'dirt', why should everthing else be procured for a similar discount?

i don't understand this logic.

I agree, I like the option of being able to upgrade to this kit complete knowing it works when installed.
Some may want to make up their own system and do their own R&D. In the end if I add up my time and money they both probably cost about the same. I am kind of old school and like to do it myself most of the time. is nice to have the choice though.

Nice Build! Nice Setup!! keep us posted!!
 

rchalmers3

Half a mile from the Broad River
Steel Soldiers Supporter
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Irmo, South Carolina
mudguppy,

Great ideas and execution on your modifications!

Will you add A/C to your list of changes?

I really appreciate the time and effort you have put into your rig and especially the photos and time to post your work. Happy New Year to you and thanks!

Rick
 

Unforgiven

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the rotors are machined, too. (i thought i mentioned that?)

anyway, the hubs and rotors are machined. from what i can tell, the rotors are machined a tad different front vs rear. i think the hubs are machined the same front vs rear, but i don't know that since they were assembled prior.

the brackets are obviously 'custom'. however, i think that the entire package is the trick - the hubs, rotors, and bracket alignment must be spot-on in order for proper alignment of the caliper on the rotor. besides that, there are certain other 'proprietary' mods done to the brackets; i'm guessing heat treating or other hardening methods so they will survive under the kingpins.

the short answer: yes, everything is 'off-the-shelf', but everything is modified.

here is a rotor part no.:
Thanks.

Yes I noticed the fronts & rears were different. I'm curious to follow this thread for your long-term feedback wrt off roading, brake fade, etc.
 

Unforgiven

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oh, and i don't take this as a personal dig or anything, but i don't understand this comparison.

much like the winch discussion, just because the truck is obtained for 'dirt', why should everthing else be procured for a similar discount?

i don't understand this logic.
There is no logic. I'm stuck in the 1980's price-wise. Inflation under Clinton, Bush, & Obama is just starting to digest mentally with me.

Too many projects, too little money. I was just curious about the markup on the kit.

But I ran across that cross-drilled drum thread last night. I might try that first. Just exploring brake options right now.
 

militarysteel

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well you are going to get a few different opinions with this truck, Some might be jealous, Some might think your motivation is bad to the bone, Some might say you murdered a perfectly good truck, Some might say MY GOD MAN are you made of money?,

i guess with any part of this hobby we all have, as long as you have fun, because life is short. :)
 

Flat Black

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Travis, lemme know if you dont want this in here and I will take it out:

Budget Rockwell Brakes: Free Rockwell Wheel Brake Recipe for Rims Smaller Than 20" From Patooyee's Parts - Pirate4x4.Com Bulletin Board

EDIT: These brakes are for rock crawling buggies on trails. People were asking about brake options so I posted that link to show there are options available. I am not suggesting you should use these on your truck at 55 mph on the highway. As you can see, the design parameter was to put disc brakes on a Rockwell axle with a 16-17 inch wheel, not a concern on a deuce, where larger components could and probably should be used.
 
Last edited:
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Flat Black, the problem with someone running a Deuce with the rotors and calipers listed in that link is that they will not handle a Deuces weight unloaded and certainly not loaded. A Lincon navigator weighs less then half of a deuce. The brakes would fade quickly and probably warp after one panic stop.
 

mudguppy

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Travis, lemme know if you dont want this in here and I will take it out:

Budget Rockwell Brakes: Free Rockwell Wheel Brake Recipe for Rims Smaller Than 20" From Patooyee's Parts - Pirate4x4.Com Bulletin Board
that's certainly 'budget'. nothing wrong with them and the crafstmanship looks good. i semi-agree with the capacity - i think that they would indeed stop an un-laden deuce (3 axle) or bobbed (2 axle). but loaded or towing might be too much. this is speculation, though.

the major difference behind DIY efforts like this versus Steve's brakes is fitment into a smaller wheel diameter. on an MV, this just simply isn't a concern. that means there isn't caliper-trashing grinding efforts and you get to take advantage of larger diameter rotors. that guy did some nice work, though. i wouldn't be afraid to run it on the street... in a lighter truck.


UPDATE:

well, since i've been back from FL, i haven't been able to spend much time wiring the truck. i was out yesterday afternoon and some today finishing up the gauges. yesterday i installed the Dipricol Optix boost and egt gauges that i salvaged from the Dodge project in some universal 'bullet' mounts. i also removed the OE oil, speedo, tach, and temp gauges and replaced them with VDO Vision series - don't worry, i'll take pics of it all.

wiring it all takes some time, effort, creativity, patience, and electrical connectors. by the end of yesterday afternoon, i was out of the last two items. and since it was colder than a well-diggers taint yesterday and today, numb hands make intricate work 3x as long and difficult.

but before i quit, i was able to get power to most to do a function check. the two that have me worried the most are the programmable speedo and tach. i put the transfer in 'N' and trans in 5th and slipped the clutch out - the needle on the speedo moved up to ~20mph. movement is good; the rest is in the programming.


however the tach did nothing. but it needed a 2nd power wire that wasn't run yet, so i left it for today. and today (with more connectors) i hooked up the lighting circuits and ran that 2nd power wire. illumination is on and the all look fantastic. still no life out of the tach.

so, as we speak, i'm currently chasing down possibilities. i'm using the 'Stator Output' on my external regulator to drive the tach - VDO tech said this would work. well, it ain't. then i realized (while pondering this on the warm couch a little later) - i have 4 inputs on my regulator:
  • F - field
  • A - voltage sensing
  • I - switched power
  • S - stator
however, the 'S' is not used as i have no stator output on my alternator. the realization/assumption is that i can't have a 'Stator Output' if i don't have the regulator hooked up to the stator, can i ??? to me, this explains why the tach is motion-less. yes???

so now i'm researching ways to utilize the OE dodge engine speed sensor and how i can wire that to the tach. i'm pretty sure i need to utilize/adapt/build a voltage regulator to drop the voltage to 5V to feed the sensor. then i have a few options of how the tach might accept this as an input..... then i have to program it to actual engine speed.


... and i'm gone all this week. ... and will be falling down a snow-covered mountain next weekend. so who knows when i'll be able to get this resolved. aua

oh, and i still haven't adjusted the vavles, wired in the headlights or aux lights, back-up lights, work lights, added the 2nd tool box ...... :roll:
 

Trango

Member
735
23
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Location
Boulder, CO
Hi Travis,

What was your throttle linkage? Need to put an accelerator pedal in my project to mate up to the P pump and running into clearance issues with the linkage on the stock pedal, so I need to find an entirely new system. Any tips?

Best,
Bob
 

mudguppy

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duncan, sc
i actually re-used the deuce OE throttle linkage. i ended up cutting about 8" or so off of it, and i simply re-threaded it and put the OE adjustment linkage back on.

the fitment is a bit tight; i loosened the joint at the pedal end to re-align the bend in the linkage. it now just passes between the lift pump inlet and priming plunger.

i removed the complex throttle linkage system on the 5.9 IP. the final piece of linkage that is bolted to the side of the IP was retained and this is where i attached the deuce linkage. lemme find a pic or take a new one.

same story with the fuel shut-off cable and idle control; shortened and re-used OE.
 

m880 unimog

Member
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Location
england
that is one of the finest looking builds i have seen for a long while.congrats on having the vision and the grit to go all the way.in fast time and a very,very reasonable budget IMO.
im just kicking off with my 5.9. transplant/hybrid,so all 14 pages were read with great interest.
thanks for the time and great pictures-enjoy OWNING the highway.
 

Trango

Member
735
23
18
Location
Boulder, CO
Travis,

Thanks for the note. Smart that you're reusing the stock accel pedal - that's certainly what I'd do if I had the room and the linkage didn't hit the motor mounts for the 8.3. :(

That said, I'm thinking about keeping the solid linkage. Lord knows that the cab doesn't move on these trucks compared to the frame, and I think it may be easier to just put a pedal on there that has the requisite throw and make it work.

Best,
Bob
 

spicergear

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Millerstown, PA
That is an awesome truck build!!!

I put a Hydro Max system on my crane truck and I love it, love it, love it! Towbarring another deuce truck w/w bring me to a total combined weight of around 32,000lbs and the Hydro Max will slow me down with my big toe and I haven't any worries since it's factory rated to 43,000lbs gross.

My question is when I was looking to do this I looked into hydroboost and it just didn't have the braking power multiplication or GVWR near to the Hydro Max. To do the job the H-boost system would be at like 90% of it's total ability all the time stopping the truck. I know your bobbed truck is a little lighter but the massive 1600's are a far cry from anything the F550 ever saw and combined with the weight of the truck...is getting up there in the actual leverage and mass over the brakes. I had talked to a h-boost company that deals specifically in retrofitting h-boost to vehicles. They had all kinds of info on all the factors contributing to braking efficiency and they were actually the people that pointed me to Hydro Max as juice brakes with nearly triple the brake multiplication of h-boost.

I am NOT picking apart your truck...just referencing what I had come across when researching brake systems. Your truck is GREAT!!!
 

swbradley1

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MG, that is one good looking build. You did it your way and it turned out great.

Bring it to Haspin this year.

:)

sw
 
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