PaPa's 69 F100 Explorer Coyote 10R80 swap

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Here are some more shots.

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I purchased some reproduction copper washers from NPD for the third member nuts. About 1/3 of them split when I torqued them down to the middle of the spec. I don't think they are a very good repop. They seem much thinner than the OEM ones. I bought a copper washer assortment but the ones I needed were not in it. I made some careful measurements and finally found some that were thicker then the ones from NPD and are the correct size. As it turns out they are also the same as the ones used on the front brake caliper lines. (from a dent side)
These worked just fine. These are probably not needed for most of the trucks as a dab of silicone will probably do the same thing.

washers.JPG

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Next I installed the rear axles. All those pretty paint markings are now hidden from view. I then moved onto the rear brakes. I powder coated the wheel cylinders. I plated and painted the pieces as close as I could to the original plating/paint. Some of this was difficult to determine. There really is not a lot (or any) information available so this may not be exact. They are not the same as Mustangs of which a lot more information is available. I cleaned up the pieces and was able identify most of the colors and plating. One exception were the primary shoe springs. I found no evidence of paint at all on either the left or right spring. This leads me to believe it was originally black or natural. I opted for black to stave off rust. On Mustangs this spring is yellow.

brake parts dirty.JPG

brake parts plated .JPG

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Here is the assembled brake assembly.

brake asembly 1.JPG

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I was originally going to buy rear drums. The ones I removed were really rusty and greasy. However after taking a good look at them I found that they were original. When I measured them I discovered they had never been turned, and the braking surface was in real good shape and would only need a light clean up. So decided to invest the time to clean and powder coat them.

brake drum raw.JPG

brake drum 2.JPG

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I then took the drums to work where we have brake lathe. The drums had never been turned so there was plenty of meat on them. After the first cut I discovered it was badly out of round. After .030 removal it became obvious it was not going to turn out. I chucked up the second one and it was as bad or worse.
After all that work I will use them.

brake drum 4.JPG

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Next I started installing the emergency cables. I was able to find NOS cables for the front and Right rear. But I could never find the Left rear.

ebrake 3.JPG

9 inch 4.JPG

ebrake 1.JPG

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The equalizer bar came next.

equilizer 1.JPG

equalizer 2.JPG

ebrake 2.JPG

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When I assembled the front brakes I got in a hurry and installed them right out of the box. They have started rusting.

disc brakes rusting 2.JPG

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I took it back down. I disassembled the calipers and powdercoated them. I rebuilt them with a new seal kit.

caliper 3.JPG

caliper 4.JPG

caliper 6.JPG

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Getting the piston back in is the tricky part.

caliper 8.JPG

caliper 9.JPG

caliper 10.JPG

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The rotors were replaced with Dynamic Friction Geospec rotors. They have a nice anti-corrosion coating through out. Much Better.

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Making brake lines came next.

brake tubing 1.JPG

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Some of the tools I used.

brake tubing 2.JPG

brake tubing 3.JPG

brake tubing 4.JPG

[jzjames]

Ha! What a great restoration! Just caught up on all the posts and pictures. Very interesting, and appreciate the effort to post everything