Abstract: A process for making a light-weight, heavy duty steel piston for a disc brake. The initial blank is formed to include the piston nose radii and angle. The blank is then simultaneously rolled by three rollers, one of which rollers forms the piston boot groove, another of which rollers maintains the outer diameter of the main portion of the piston, and the other roller of which forms near the outer end of the piston an overall diameter which is less than the main overall diameter. During the rolling step, the metal deforms to form a contour opposite the base of the piston boot groove such that the thickness of the wall between the contour and the base of the piston boot groove is smaller than the thickness of the main portion of the wall, but yet is strong enough to withstand heavy duty disc brake operation throughout the life of the disc brakes.