Now comes the real fun part. We need to cut along those lines to end up with a pentagonal hub for the rotor to mount on. How you cut it is up to you. I’ve had very good luck using a porta-band saw. The hubs are very soft and easy to cut.

Once you get it cut, take a grinder or file and clean up the edges so they look nice. I then painted mine. I don’t have any pics of the front hubs here, but you can see them later in this article.

Now press in the new lug studs. Be very careful that the hub is properly supported as they can and will break if not. I use an old rotor that I’ve drilled the holes out to ½”.

And on some hubs you may have to grind a flat on one side of the head of the stud when doing the front so that it will fit properly. Pretty evident when you see it in front of you.

Now we get to fabricate the front caliper brackets using SJ413 caliper brackets. That can be kind of tricky. The existing holes will not fit on an LJ and new ones must be drilled. And the new holes overlap the old holes, which make them hard to drill properly (more like freaking impossible). In his excellent post on a disk brake conversion, “lil beast” filled the original holes with bronze and then drilled the new ones. (http://www.lj10.com/forum/viewtopic.php?t=737)

I took a different approach. I took a steel plate, laid the SJ413 caliper bracket on it and marked the four mounting holes and the large center hole. I then, using the original LJ front Backing plate, lined up the large center hole and marked the LJ mounting holes on the same piece of plate. I then drilled small pilot holes for both sets of mounting holes. Then I drilled the SJ413 mounting holes out to 3/8”, inserted some long bolts and welded the heads to the plate.

This is the plate: (caveat: these pictures were taken long after the project was finished, so the plate is used)

Then I sawed off two of the bolts to be the same height as the caliper bracket, thus:

Then the caliper bracket is bolted firmly to the plate with the intact bolts.

Then I drilled thru the plate from the back side, starting with a small pilot and increasing to a 5/16” final hole.

Then I turned the caliper bracket around so I could drill the remaining two holes.

And this is the finished bracket:

Now we want to bolt the bracket onto the knuckle, but we need longer bolts than came out. Time to go dig through your bolt bucket.

And here’s our new little beauty bolted on. Don’t it look nice?

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