I'm kicking around swapping in some Explorer rear discs since it sounds like they're the only swap that has a decent E-brake. I'm also aware that they're set up for the medium bearing rear ends. How hard is it to accurately expand the holes for my big bearing ends?

Justin, if you do these, I'd love to help/watch. I have all the parts in my garage to do this. Granted, my Bronco has the right rear end for it to be a bolt on. I've heard I might need a spacer though.

Can do! Good thoughts, anything else I might need for this?

I've seen billet steel "Torino" bearing ends on eBay for $60

Been wondering if changing them would be better than oval shaped holes or welding and drilling or .....

The challenge with those is that you need an alignment bar to install them correctly. The long term dream is to build a 9"/14 bolt full float hybrid, so if it isn't easy I'll just stick with drums.

I'd say you could just "key hole" the existing bolt holes and you should be good.

How close do the tolerances need to be.?

Justin, if needed, I can loan you a backing plate so you can see what it might need.

I think the lack of enough axle brake offset is going to be the bigger challenge.

So do the brakes need to go out or are longer axles needed?

I'm using an axle out of a 77 F150. How much longer do the axles need to be over stock?

As measured from the axle end to WMS?

OK, I ate lunch at home and popped a drum off to measure. Looks like you're right. I'm seeing a hair more than 2 3/8 from the backing plate to the face of the axle. If I move forward with this, it looks like all I'll need to do is figure out whether my existing e-brake cables will work and open up the mounting holes. How precisely do those holes need to be cut? It seems like a paper template could be used to mark it and a die grinder used to carefully expand the existing holes.

Use a bearing retainer for your template. You could even tack an old bearing to it to keep it centered.

That's a darn good idea. Thanks!

Over on CB there was a thread about the possibility of 2004-2007 E-150 van rear disc brakes being workable.

Would need at least 16" wheels.
Rotors already 5 on 5.5
Bigger diameter so maybe better parking brake?

Food for thought for the junkyard spotters?

Opening the center of a backing plate is pretty easy. I did it on my girlfriends TJ when I put grand Cherokee disks on her jeep. Of course I used a Bridgeport with a boring head. (My dad has one)I'd be happy to take a crack at this since for you but unfortunately it would have to be after June 23rd when I return from my Rubicon trip. I'm in panic mode trying to get everything ready currently.

I just keyholes the holes , center of backing plate was fine, I used explorer parking brake cables. One thing to keep in mind is to clearance the center hole of the rotor, and the axle end. Mine machined 1/16th so they would fit inside the rotors.