The Chick Magnet gets bigger brakes

In the past I’ve shared my adventures with my 1992 Toyota Pickup truck, a.k.a. the Chick Magnet.  I’ve had the truck for about sixteen years and it has been a journey of repair and improvements.  It got the Name “chick magnet” through its unfortunate habit of being rear-ended by women drivers.  After four times things have settled down and I have been enjoying it as my daily driver.

red pickup truck

Its been re-painted, re-upholstered, it has had its suspension rebuilt, and it has a wonderful engine built by the folks at LC Engineering in Arizona.  The only area that it seemed lacking in was brakes.  The stock brakes were essentially adequate, but as more power was added to the drivetrain they developed a bad habit of pulsing and feeling a bit weak.

I looked all over for “big brake” options.  There are some nice aftermarket solutions that use Willwood calipers and larger rotors.  My problem with that solution was that it required larger wheels, usually 17” rims.  I just didn’t want to make that investment all over again since I changed to XD122 Enduros in 15” and liked the look as it allowed me to keep a wide enough sidewall that it still looked like a truck.

So what to do?  I explored several forums and learned what other Pickup owners had done.  Most of them were 4WD trucks and mine is a 2WD.  Others had swapped out their 22RE for a Chevy LS engine.  Buried in all the information was a 1 ton version of my truck that had much larger calipers and bigger rotors that just might be a bolt-on swap. Would it really be a bolt-on?  I decided to locate the parts and give it a try.

Rockauto had some 1-ton PD66 type calipers and rotors for a very good price.  If I was going to gamble I would at least try there so my budget wouldn’t take a big hit if it was a mistake.

With larger calipers that had much larger pistons than my original calipers I knew that I would need to upgrade my brake master cylinder from the stock 7/8” piston to something larger so I found a Toyota one that had a 1 and 1/16” piston to replace it with.

Then came the weekend that I had time to put the package together.  My hope was that since everything was Toyota that it would not mean fabricating a new caliper bracket or drilling and tapping new mounting holes.


The above photo shows the 1-ton calipers on the left and the originals for my 1/4-ton on the right. The new ones are not only larger, they have a nice cadmium plating to help keep them looking good for a long time.

I removed the original sized rotors from the hub and bolted up the larger 1-ton rotors.  Everything fit like a glove and they even were not too large for the splash shields.


Above are the stock rotors and hub with the mounting bolts removed.


The new rotors bolted to the original hub just fine.


As you can see above, the big rotors still fit the factory splash shields even though they are a larger diameter.


Here you can see that the 1-ton rotors are a only bit larger in diameter than the stock, but that size differential makes a big difference.

The only thing that needed modification on the splash shields was the area where the larger caliper brackets needed to bolt up.  A little work with some tin snips and a ball-peen hammer and the brackets fit perfectly.


Then the new brackets were bolted up.


Followed by the pads and new calipers.



There was only one piece of fabricating required.  There is a flex hose brake line that connects the the hard line on the caliper to the hard line on the chassis.  The hard line on the caliper was kept in place on the old caliper by a metal bracket.


There was a different metal bracket to work with the 1-ton calipers, but Toyota no longer has them available and I was unlikely to find a 1-ton truck in a local recycling yard.  So I got new hard lines for the calipers, they were the same as the ones on the old calipers, and cleaned up the metal brackets.

What I needed was a piece to bridge the 1.75” gap between the small caliper bracket and the mounting hole on the new, big caliper.  So I fabricated the metal bridges.


I made a square hole in one end so that I could use a smooth headed carriage bolt on one end.  A regular bolt head would have interfered with the caliper bracket mounting bolt.


A nylock nut was used on the carriage bolt so there should be no danger of it vibrating loose in the future.


Above is another view of the caliper and the bracket bridge where you can see where it could have interfered with the caliper bracket mounting bolt.

All the bolts were checked for proper torque and the new master cylinder was swapped in place of the smaller stock unit.  All the hard brake lines matched up perfectly to the new master cylinder and the system was bled before a test drive.

So how are the new brakes?  Wonderful.  I get a lot more braking capacity and the pedal feel is even better with the larger bore master cylinder.

The guys at the shop joke about it being the first pickup truck that can do an “endo”.  Actually the performance is so good that the brakes are easier to modulate and the brakes are so heavy duty that I probably won’t need to replace the pads for another 100,000 miles.  They are easy to modulate and don’t grab and lock up. Instead they have plenty of reserve capacity and great pedal feel.

This entry was posted in Automobiles, Car Stuff, Care and Feeding, Cars, Life and Cars, Modifying Cars and tagged , , . Bookmark the permalink.

9 Responses to The Chick Magnet gets bigger brakes

  1. Jim's sister says:

    very cool.

  2. Elton Park says:

    Hi Jim,

    I have enjoyed reading all your posts regarding your 92’ pickup as im eagerly waiting to pick one up tomorrow. Just wondering how shes been holding up all these years?

    Hope you and her are safe from the virus that’s around.



  3. jimsgarage says:

    The Pickup has been great. With the engine built by the folks at LC Engineering it has lots of power for a light weight pickup truck and is the perfect daily driver.

  4. Joe says:

    Hello Jimsgarage,
    Thanks for the information on a brake upgrade. My son and I did a similar upgrade to our 2002 4Runner with the Tundra brake calipers and rotors. Up until last November, I was driving a 1993 extracab that I had bought new. Sadly, on a rainy day, I was a little slow to realize the light was red, applied brakes, and slid into the intersection. A complete stop was achieved through the use of a 2018 Ford pickup. Fortunately, nobody was hurt (other than general aches from a sudden deceleration). Unfortunately, the ’93 pickup was done. There are probably a few places and folks that could resurrect it, but it is beyond my skills for sure. So, I am now the owner of a much more used ’95 extra cab pickup. Braking is one of the areas I always felt the truck could do better in. I am very interested in the upgrade you did, and would appreciate any information/details you could provide on the parts. I did a search for PD66 in Rockauto, nothing came up directly, will continue looking there. Specifically what model/year is the Toyota 1 ton you said matched up to your truck, and which model did you pull the master brake cylinder from that bolted onto your truck? Sorry for the long reply, guess I’m still missing the truck I had for 28+ years.


  5. jimsgarage says:

    Joe –
    Sorry to hear that happened. It would be quite a loss to me if the “Chick Magnet” were to have a similar fate. I know that the years that I looked were right aroun1992-94. I am at a loss to think of another source, and it could be that Rockauto sold out their inventory. Maybe a parts store would be able to match the bigger caliper with the info in the above. I read through the specs on master cylinders on Rockauto until I found one that I felt was large enough diameter to deal with the larger calipers. I will pull my records and see what I can find that might help you more in your search.

    • Joe says:

      Yeah, not sure what it says about me that I am still mourning the loss of my truck… Appreciate the quick reply and your records search efforts. Do you happen to recall what the 1 ton truck was that was also a source of possible bolt on parts? I will do a search for one of those as well, maybe I’ll get lucky for donor parts, maybe! I have to say that if the stopping improvements were anything like the difference the Tundra brake upgrade did for the 4Runner, it is well worth the time and effort. Thank you again for any information/assistance you can provide.

  6. Joe says:

    One more question, so the master cylinder you used was also from Rockauto, not a donor from another Toyota?

  7. jimsgarage says:

    Joe –
    I checked through my paperwork and here is what I’ve been able to find:

    The master cylinder was supposed to go on a 1994 Toyota T100 2.7L 4cyl. It is a Cardone Select 132530

    The brake rotors are Raybestos 96027R. I also used Qualis 31210 rotors

    The calipers themselves can be tricky as they are different left and right, and I may have gotten loaded sets (with pads).
    One record I have shows Autospecialty / Kelsey-Hayes 4056087, 4056085 which I believe is for an ’88 Toyota Pickup 2.4 ltr that was a 1 ton model

    I also have a record of Beck/Arnley calipers 0770964S, 0770963S (left and right). There was also a listing of alternate OEM numbers: 0760964, 4773035070,FRC10259, RWC10259 and the other side:4775035050, FRC10260, RWC10260
    Maybe you can find a good parts guy that can help you.
    As far as missing the truck, well why shouldn’t you?

    • Joe says:

      Wow, thank you for the very detailed information. Hopefully someone is still supporting those parts. Interesting that the left and right are different (not mirror images I’m guessing). Wonder why that would be. Well, I’ll probably figure that out when this project moves ahead. Thank you again for all your time and efforts today.

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