Custom Brembo Caliper Bracket Part 2 - Heat Treated 4140 - Largest Tormach Part So Far

Custom Brembo Brake Caliper Bracket - about a year ago I made some custom front hubs for a customer who wanted to put Camaro wheels on his 97 Silverado pick up. Now he is updating more of the front end and adding Brembo Brakes to his 97 Chevy Silverado. To make this all work with the new hubs he needed a custom bracket to mount the brake calipers.

The customer designed the part in Fusion 360 and I used a combination of manual milling on my Jet JMD18 Mill Drill to prep the stock and my Tormach 1100MX CNC mill to make the parts. Had a few challenges along the way with a part this large. The prototype in 6160 Aluminum was easy compared to the final parts in heat treated 4140. I had to totally change my machining strategy in order for my Tormach 1100MX to manage the harder material. Also learned how to step bore a large hole to rough it out for a countersink, then finish bore the countersink with an 82 degree countersink bit. In the 4140 the low RPM and high feed rate broke the tip on the countersink in minutes, thankfully I could feed it further into the bore to finish the countersink.

Overall, I am really happy with how the parts turned out. It took considerably longer to machine the heat treated 4140 than I anticipated but the Tormach got it done in the end.

Work holding is done with a Glacern Machine Tools 5" vise. Probing with a Haimer 3d Taster. Cutting with GARR end mills.

Thanks for watching!