Brake Shields

Up next, I decided to make new brake shields, the original pieces had a few problems.  They were rusted and smashed, they were sized for the original 10.1" diameter brake rotors, and they were stamped to be identical so there are unused holes on each side.

The first step was to measure the originals to get all of my dimensions correct.

Then I cut blanks from 20ga steel sheet. The fronts are sized for my new 11" diameter rotors and the rears will be sized for 10.1" diameter rotors.

Inked up and holes laid out

I wanted a lip around the outside, and decided to use the hammer forming method.  I turned some plywood blanks on my lathe so they would be perfectly round:

After the first one made a complete mess, I got out a shop vac!

Note the old brake rotor I'm using for a fixture!

I clamped the steel sheet in between the plywood hammer forms.

After a considerable amount of hammering and slapping, I had a flange turned on the disc.

Fast forward a few steps. I trimmed them to shape, pressed in some countersunk holes, and shined them up!

I trimmed them even further to match the contour of the caliper carriers in the front and rear.

After a final trim of the flange and some fine tuning, they were all finished up!

Much improved!