repairs made just in time...
ok, you aren't going to believe this. No joke here, this is for true.
I disassembled the brake unit, well, I cut it off the truck, took it to the work bench and figured I'd just replace the bent and twisted carnage of what was left behind after I had abused it severely. I couldn't believe my eyes! I cut the shaft and removed the butterfly disk piece which was still welded solidly (of course) to the shaft. Now the bizarre part...the shaft had broken, and looked like a impact fracture in a piece of quartz rock! No kiddin'! At first I thought it was melted, God forbid at that distance from the turbo it melted!)
It broke like a barberpole. The new shaft is of course considerably larger in dia. (.312") and I only removed about .070" with the mill to install the new disk. Instead of welding it on this time, I got brave and figured I'd try my hand at breaking a couple of 6-32 taps, so I tap drilled the shaft for 5 screws, not ordinary ones either, no sir, (Hardened, socket head cap screws mind you.) Then decided I wouldn't weld on the arm assembly, hell no, let's find a chunk of billet aluminum and mill one out that looks cool. So, 2 hours later I have what you see in these pics. The biggest headache was die grinder cutting the pipe off, again. I only broke one tap, had to start the shaft piece only twice and the finished product is considerably nicer looking than the original prototype.
(I can see why these damn things cost so much, it's hard to get calm people to build them! Postal workers need not apply... LoL)
The tests are coming. Here's some pics to drool over. I'll leave for Modesto with a trailer load in a couple of hours. Wish me the best.