Brakes and other jobs

I’m so close the end of this….

I’ve made a chunk of progress though it doesn’t all show. The main jobs left to do from last time was sorting the wheel placement and fitment. I then also need to fit the brake calipers.

1. Front axle
I had the axle machined down to the correct length. This meant I could finally test fit the wheel and get the correct spacings

2. Front axle spacers.
The local engineering shop also made up two more spacers for me, once I had worked out what size wheel spacers I needed. I got them to machine down the existing spacer as it was quicker for them. They then created the second one.

3. I picked up some new caliper bolts as the calipers didn’t come with any. This allowed me to fit the calipers and see if it would even work!

4. The original petcock was on it’s way out so I tried to find a suitable replacement. After much research it appeared a Suzuki GS450 one would work, so I ordered one. It turns out it will fit the tank perfectly, but you cannot get it the tank back on the bike! In then end I just put the petcock in with the tank in place. This creates future headaches when removing the tank, but it will have to do.

5. Disc spacers.
With the axle and wheel spacers in place I could finally work out what to do with the discs. As they were touching one side of the brake pads on each caliper. It was around 1.5mm out. I tried to find some suitable disc spacers, but couldn’t find any. In the end I just made my own. In the end they worked perfectly and didn’t take me too long to make.

6. Brake hoses
With the fitment of the brakes I could finally get the brake caliper hoses ordered. I went with some nice Venhill ones like I had used before.

7. Mudguard mounts
I’ve not finished this yet, but after various attempts I think I’ve got the design sorted. It uses some round 6mm aluminium, I bent it to shape around the rear tire to get the perfect bend. I tried to hammer out mountings, but found it far to hard to be perfect. So now I am using some little brackets that I’m waiting to arrive. The pics give you an idea where it’s heading.

8. Speed sensor
The final job I’ve done was to find a place to mount the new magnetic speed sensor. In the end I’ve used a longer cinch bolt on the bottom or the forks. On the extra end section I’ve mounted the Koso speed sensor using the p clip to get it in the perfect place, I then routed the cable using the brake hose as a path for neatness.