[MatosMiata]

Got the basic shape of the bracket components cut out today using the angle grinder (which totally sucked to do). I will finish the shape tomorrow using a bandsaw and benchtop grinder. Unfortunately, both of these tools currently still reside at my parents' house (I need to make room in my garage for the bandsaw and I need to buy my own benchtop grinder).
20210403_201305 by Jose, on Flickr

 

[MatosMiata]

Paid a visit to my parents today. While I was there, I took advantage and ground the brackets to final shape on their benchtop grinder.
20210407_153002 by Jose, on Flickr

Here is what the final assembly will look like in metal
20210407_155758 by Jose, on Flickr

Here are the parts progressing slowly (I would take breaks and switch which piece I was working on; they would get really hot and I forgot my gloves)
20210407_155812 by Jose, on Flickr

 

[MatosMiata]

Here are the final ground parts next to the templates
20210407_175331 by Jose, on Flickr

As you can see, they are pretty much spot on
20210407_184403 by Jose, on Flickr

I can't wait to get this all installed
20210407_184429 by Jose, on Flickr

 

[MatosMiata]

I guess I'm a proper surgeon with a grinder. Can't wait to get some CNC machines so I don't need to perform so many manual surgeries though lol!

 

[MatosMiata]

Just put in an order for all of the hardware I will need for my brake brackets and calipers. That, and some slightly thinner metal that I need in order to properly space the bracket. Once that comes in, I can weld the brackets together and install them on the axle.

 

[MatosMiata]

I got some slightly thinner metal sheet that I ordered for the brake brackets. Managed to make the final spacer pieces needed. Tomorrow, I plan to assemble the brackets tightly just using bolts and doing a test fit of the caliper. If I am happy with it, then I will weld the bracket together.
20210412_233319 by Jose, on Flickr

 

[MatosMiata]

I was finally able to test fit the calipers using the metal bracket. For whatever reason, despite all my other hardware arriving from McMaster, the 3/8-24 nuts I need to hold the brackets to the axle won't come until early May. Of course, Lowes and Home Depot don't carry the fine thread stuff so I was stuck for a bit. Luckily, my local Autozone had them. There was literally one pack left and it only had 4 of the 5 nuts it was supposed to bring. Clearly some dude couldn't be decent enough to fork over the $3 for the whole pack he needed and he just stole one smh. Oh well, I only needed three for my test fit and the missing one got me a 10% discount lol. I wish I had thought to forget what Ford used on their stock bracket and simply used the closest metric bolt to the hole size, an M10.

Anywho, it is nice to finally see the caliper mounted with the metal bracket
20210415_152819 by Jose, on Flickr

20210415_152821 by Jose, on Flickr

 

[MatosMiata]

It initially looked like the caliper wasn't properly centered above the rotor, but a quick adjustment got it set right. If anything, I can also add a thin washer between the caliper and mounting bracket to shim it out slightly. We will see where everything ends up once the bracket is welded together.
20210415_152833 by Jose, on Flickr

 

[MatosMiata]

Once the brackets are done, I can clean and paint everything, including the calipers.