started with this air powered die grinder and a carbide bit for aluminum:


switched to this, removes metal MUCH faster, but bulky and harder to work with:

 

I didn't believe people when they told me that this job was going to take "hours". well, they were right, it is a real p.i.t.a. the worst part is that I'm still not done. I need to get the correct lug nuts and bolt the wheel on (centered properly) and see what areas need more work. but I am getting there... what a tight fit! somebody should come up with a rear brake kit to make this swap easier. enough talk, here's the pictures:

before:


after:

 

before:


after:

 

before:


after: (this is actually a shot of the other side of the truck, but a clearer picture)

 

before:


after:

 

here with the piston's dust boot removed you can see how much material is left:


here is another photo with the dust boot installed, it requires a little trimming too:


installed side shot:

 

before:


after:

 

back side views:

 

here with a light on the other side, you can see how little clearance there is:




that's all folks!

later,
chris

 

Any chance of snapping one of those under hard braking? They're looking kind of thin now.

 

holy crap!

Screw that Brakes are Damn important, Best investment money can buy. (you can go fast, but you MUST stop)

I just bought 16" with Hoosier slicks.
after researching how much material had to be removed I didn't want to mess with it. Now that I see your pictures! DANG.


Helluva post though. goof detailed Pics!

 

yeah....really thin

 

it's not as bad as it looks.

here are some pictures of the inside of the caliper, you can see that there is still plenty of metal remaining, these calipers are pretty beefy to start with:




also, there are lots of guys that have been running these wheels for over a year now with no problems.




later,
chris

 

Bogart d-10s rock!! I got a set and love them!!!!

 

Looks great man. I dont see it snapping. There is really no thin parts. Just bulk taken off the outside. What kind of slicks/snowtires are you gonna put on there?

Ray