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Old 05-08-2009, 11:46 PM   #24 (permalink)
dremd
EV OR DIESEL
 
Join Date: Dec 2007
Location: South Louisiana
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Eco-Modders first Brake upgrade.

I totally forgo that I promised my dad that I'd build out his disc Brake today; decided to take some pics since I'm in the mood today.

Here it goes

Step 1 Caliper


Step 2 Free hand out an estimate of the caliper bracket on to scrap steel


Step 3 Plasma out estimated caliper bracket


Step 4 Start making adjustments to rough shape with bench grinder


Step 5 Mount Wheel with disc brake to bike


Step 6 Determine that fender bracket is in the way; modify design accordingly.


Step 7 Finnish fitting caliper bracket


Step 8 Prep to drill holes


Step 9 Line up for hole #2


Step 10 Tweak to clear both holes


Step 11 Determine where to cut off bracket taking a few things in mind
1) Swept area of disc
2) Suspension movement (can't ever bottom out in caliper as geometry changes)
3) Must clear Fender bracket



Step 12 Plasma it down till it fits Then see that your alignment is Fubar; Start bending till it fits


Step 13 Give up looking for 4 1/2" grinder and just weld through the paint for ugly weld


Step 14 Paint (sorry got dark)

Step 15 Determine that brake cable is way short (as expected) Begin search for longer cable.

Step 16 ride it while holding brake in one hand, clutch in anther, throttle in another and stop with only 1 hand on bars lol; it works pretty well.

To be continued. . . . . .
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2016 Tesla Model X
2022 Sprinter
Gone 2012 Tesla Model S P85
Gone 2013 Nissan LEAF SV
2012 Nissan LEAF SV
6 speed ALH TDI Swapped in to a 2003 Jetta Wagon
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