New front brakes

Heya,

I picked up an aprilia rs125 disc & yzf1000 caliper,
Now i just need to attach it all.

Disc needs to be spaced away from the hub a lot, then i need to make a bracket to attach the caliper to the fork.

I plan on having it this close:


The bracket will be 8mm aluminium. Does this look alright?

 

Oh man, sign me up...

Are you going to do dual disks?

Seriously, you could probably sell these to people if you made more than one set.

 

Hope that is a climate controlled place for those guitars.

 

I had a whole thing typed out about forces and loads and whatnot, but I deleted it because it depends more on what shape the adapter is going to be. It should be a rough "C" shape running along the bottom of the caliper itself. I had an adapter made to fit an EX500 caliper on a Kawasaki H1 about ten years ago, and thats what it looked like. It helps to distribute the braking forces into the original mounts.

 

you want to space the disk half way and the caliper half way so you get less
flexing through shorter bolts in the spacers

 

Cool. Didn't a Scottish racer on here do something similar with his 550 race bike?

 

cool, in to see how it turns out!

 

i cant picture it, but mine looks like this:
This shape was picked as it hit all the bolt holes and got out of the way of the protruding caliper parts.
I made it (and the disk spacer) out of an old imac stand.

Orange-n-black, yeh thats my loungeroom. I cant begin to describe how"challenging" my workspace is.

Kdub- yes I'm totally copying the scottish racer brakes. I sent him a PM to get more info, but he never responded, probably because he sold the bike and moved on. I'm also keen to copy his spokes, but at the normal diameter rim sizes. (don't have the cash for that yet tho)

Polock, yep the disk needed to come away from the hub so the caliper could clear the spokes (alloy spokes.. whatever)

I'll put up a photo when its all complete BUT
I need to make a spacer behind the bracket, to bring the caliper back towards the disk. (or if I had started with much thicker material, I could have just shaved some thickness off the area that connects to the fork)

so far its £19 for the disk, £30 for the caliper, £2 for the imac stand, £20 for a monthly subscription to the build brighton hackspace.

The toughest part about making the caliper is making sure that the alignment of the bolt holes is right. No sloppy measurements.

 

if you have access to a lathe, turn some bolts to a point then use them to mark the center of the hole.
they'll come in handy for all sorts of things

 

Done.



View along the disk


from the top (dunno why I took this)


Used the aluminium base of an iMac, cut into three parts
#1 spacer between hub and disk
#2 bracket to hold caliper in correct position (ver careful on angles and measurements)
#3 spacer, the same as the bracket, behind the bracket, but with cutouts for the fork (see below)

(pre finishing, had a little more cutting to do)

 

Good job.