***I had a whole thing in TAPATALK and it totally only left minimal. Currently doing this on my computer and will upload my original write-up***
Alright, third try as this site likes to reset if I leave for too long.
Generating some interest on FB regarding this as a mounting kit to fit the Mustang GT350 front brakes onto the 6th gen Taurus, Explorer, FLex and Lincoln equivalents. Looking to keep the cost down under $500 for brackets with mounting hardware. Add in the fact that calipers and OE 2-pc rotors can be found under $200 per (plus shipping) with 1pc being around $120 per. Pads are about the same price as ours, so track pads can be had for around $120. Goodridge hoses will work with these calipers. So, you can get 15.5" 6-piston brembos onto your car for under $1500.
How this started.
I was looking to upgrade my already "upgraded" brakes on my '11 SHO (used the latter 13.8" brakes in 2015) and started looking for commonalities and easy to adapt stock brakes. I started looking at the 15" Mustang Performance Brembo setup, but ran into the issue of the Caliper having an internal crossover and no way to really swap the caliper and maintain the correct orientation (pistons are offset). Saw the GT 350 brakes and realized they have an external crossover tube and the body is symmetrical. THis means all you have to do is swap the tubes between sides and put the bleeders at the ends that used to have the tubes to keep the caliper oriented correctly with the bleeders on top. Also, radial mounting allowed me to make a good bracket that would be centered on the original mounting to keep forces in the designed places. I'm still finalizing the design to ensure it's good and I also ran into another issue with the ball joint hitting the rotor (didn't realize, thought it was a mounting bolt, but those are well within the inside of the rotor).
Here's the biggest issues I ran into and the solutions I'm planning.
1: 10-12 spindles are bigger on top due to the pinch bolt design. I contoured the bracket, but it will still require a tiny bit of grinding on some casting ridges. I don't want to make the bracket any thinner.
2: Contact with the ball joint. quick measuring and CAD and I have some 1/8" bearing housing spacers coming in the next week. Still gives good bore contact into the spindle and I don't like the idea of spacing the rotor itself out. Spacing the rotor will be required if using on a 10-12 due to the spacers currently only for the 13+ which have larger bearings. 10-12 use same bearing/hub assy front and rear.
3: 15mm spacer required for stock 10-12 wheels. Those stock wheels require the weights to be removed from inside and either run only inner lip (hammer on) or possibly move the weights as close to the spoke as possible. I'll see when I put new tires on. My Asanti ABL-12 20x9 -35 fit without issue. Had to remove the ~2.5mm washer under the caliper bolt to clear the weights on those. Really, just be prepared to move the weights on your wheels. Obviously, 20" only.
4: lug hole size is just under 5/8" (~.622), so I'm getting some 1/4" long 1/2" to 5/8" sleeves to test out. I don't like oversized holes as I've had rotors slip and "clunk" upon braking in other applications.
So here's the real break-down:
Brackets (7075 AL)
Hardware for both mounting the bracket to the spindle and caliper to the bracket and banjo bolts with new crush washers.
rotor centering rings x2
stud hole reducers x10
I have at least 10 people from FB interested and I'll likely get 25 sets made.
Pictures below. I had my prototype 3D printed which is why it's dark gray, but that is very close to what it will end up looking like.
