Custom Caliper Bracket

[binge]

I've just bought some new forks, Problem is, My caliper wont fit the fork leg, And the Caliper that is made for the forks, Is made to run with a 190mm disk.

Problem is, I'm running a 210mm front disk, And a 200mm rear disk. So there's no way in hell I am going to have a smaller front disk than back!

I've been told by alot of the parts suppliers to make my own adapter bracket to bring the caliper out, to fit over the massive disk I've got.


Now I understand that bolting a 5mm plate to the original caliper mount, Then bolting the caliper directly to this, Will upset the caliper offset, So I will have to think that one through, Possibly making a stepped mount, Or mounting it on the outside of the fork leg mounts, Then spacing the caliper to move it back inline with the disk.


My concern is, Whats the best material to make it out of, And where's the best place to get such material. I've never had to buy a sheet of Alloy, Or steel before.





Ben

[MarJay]

You don't want to use sheet, you want to use billet.

Personally this is the kind of thing that I wouldn't make myself. Its a safety critical item. A local machine shop would probably make something up for you.

I do make parts and tools myself sometimes, but they tend to be rough and ready (and out of whatever is lying around in my garage). I don't have a lathe or milling machine so cannot make stuff accurately. My stuff is usually pretty tough, but I still wouldn't trust it to hold a brake caliper.

These people could definatley do it www.pretech.co.uk but they obviously aren't very near to you, and I expect they would need the bike or at least the forks and front wheel to make the bracket.
____________________
British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F; Cheap project: CBR900RR FireBlade
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

[Ichy]

I prefer a good piece of steel rather that aluminium. I have an old BSH that explains a lot about making brake brackets. I'll scan it in if you want?
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https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[binge]

Whats a BSH? And yea, If you dont mind.

I've just been up to the garage, and found a caliper which I bought last year for the bike. it comes on a remote bracket. Hopefully the remote bracket will be big enough to use as a bracket for my caliper.


I was thinking about doing this...

Bolting the caliper to the top fork mount, As usual.

And then swing it upwards, Until it is sitting over the disk perfectly. It will only need to be moved about 10 - 15mm (gap from bottom mount to caliper).

Then bridging this gap, with a piece of 5mm steel, and a couple of nut/bolts.


Sound logical? Or am I just dreaming?



Ben

[mad4it028]

im buildng a supermoto right now ive got 320mm front disc was 210mm went to thorney presision engineering with forks wheel and caliper they charged me £20 for a perfect fit mount worth it i think
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always looking to buy bikes crashed ,unfinished projects,none runners pm me
currently riding kawasaki z1000 only bike ive ever loved

[Mudskipper]

[binge]

Bloody Hell! I might have to do that than!




Cheers



Ben

[mad4it028]

[binge]

Yea, I was gonna say. i went to an engineering shop for a custom Stem locking ring making up, And they wanted £45.



Ben

[mad4it028]

i had same thing made cost me £20 so i guess im getting good discount
now got usd forks fitted
also had a rear wheel machined down 20mm for £15
____________________
always looking to buy bikes crashed ,unfinished projects,none runners pm me
currently riding kawasaki z1000 only bike ive ever loved

[binge]

If I was up north I would get it all done for free because my Granddad is a retired machinist. He used to do the barrels on British Tanks before becoming the Manager of the place.

He's got a metal lathe and a Milling machine. Its just getting measurements to him which is hard.




Ben

[Ichy]

As promised, might be a bit more involved than you want.
____________________
https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[dougon2wheels]

im guessing this is for your fzr400,for these yamaha made two sizes of caliper....the earlier 83mm spacing and the later 100mm(im not sure what the really early 400's had)i have a set of the 100mm spaced calipers if you need them......btw the 83mm calipers fetch a lot of money as they are a good four pot upgrade for ypvs's
as for plates,nkracing could probably sort you out

[binge]

Its for my Pit bike, I dont have an FZR400.

Basically I am running a 210mm front disk, Extra stopping power for the YX150 motor I recently fitted. But the caliper doesn't fit over the disk when bolted to the forks.




Ben

[binge]

[binge]

Well I got the forks fitted up, And my caliper was going nowhere near it!

The only way I could of mounted the caliper would of been at 6 O'clock on the disk. So one decent left hander and it would touch the tarmac.


Even on a smaller disk, it would NOT have gone on. Totally different mounting design.


So I've ordered a proper 4 pot racing caliper and mount from OOracing. It is designed to fit a 190mm disk though.
But the mount supplied with the caliper is like this...

https://www.ooracing.com/store/images/uploads/FAST_ACE_BRACKET.JPG


Holes 1 and 3 mount to the forks, holes 2 and 4 mount the caliper.

So What I will do is draw around that mount onto a piece of thin alloy, But stagger the holes more, Bring them out by 10mm. This will then allow the caliper to sit over the 210mm disk rather than the 190mm disk.


I will then send the piece of alloy I made up to my Grandad in Leeds, where he can do me a billet version of it on his Milling machine.




Ben