'62 Chop, 4th Rebuild in 42 years..... - Page 7 - The Jockey Journal Board

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Old 01-31-2015, 05:55 PM   #121
2Loose
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Put the front forks together, put the wheel and brake rotor on,
and propped up the axle so the wheel can spin....

Here you can see how tight this space is, 1"....
I got that rotor right where I want it !
AND, it spins true, no wobble at all....

The caliper looks good up here....

Maybe a little further back, almost touching the fork leg....

Or maybe it should go under the fork leg ??
It looks like the mounting bracket would be smaller and fit better in this location....
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Old 01-31-2015, 09:38 PM   #122
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

It looks better in person.
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Old 02-01-2015, 10:00 AM   #123
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Under looks cleaner.
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Old 02-01-2015, 10:21 AM   #124
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by elffors View Post
under looks cleaner.
+1.
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Old 02-01-2015, 04:31 PM   #125
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by Elffors View Post
Under looks cleaner.
Yeah, I agree, and the bleeder is still on top, so no problems there. Now to just DO it!

Last edited by 2Loose; 02-01-2015 at 04:43 PM.
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Old 02-02-2015, 01:25 AM   #126
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

You can do it!
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Old 02-02-2015, 11:06 PM   #127
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Been really busy, but found a little time today to cut some cardboard....


It fits in there really well, and I have the caliper's frame located where I can drill and tap for a bolt from the fork slider's brake lug directly into the frame:


Now to make this bracket out of 1/4" steel. Wish I had some stainless to do this with.
Willy

Last edited by 2Loose; 02-02-2015 at 11:11 PM.
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Old 02-03-2015, 09:24 AM   #128
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The front brakes are coming out real sweet. I am steal all this for my Pan... the drum brakes are a joke and I would like to ride a bit harder on our narrow curving roads.
Nice BSA! Should have kept it!

Cheers
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Old 02-03-2015, 12:33 PM   #129
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

When I first narrowed that long front end, there was no room for the stock front drum brake. But like you said, Lester, they just don't work worth a damn anyway, so I rode for years without that front brake. But now want a good working brake in front, and want to keep the star hub, so went this route. I think I am going to be fine with this setup. The rear juice drum brake works great, can lock up that rear tire if I want, but I try real hard not to ever lock that up !!!
Aloha,
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Old 02-04-2015, 01:52 PM   #130
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

The first step is to get the frame for the caliper correctly located,
and drill and tap a hole in it for the anchor bolt on the fork slider.


Decided I needed to be able to more accurately align the pads with the rotor, so I
pulled off the caliper but left the pads loaded in the frame, transfer punched the center of
the fork slider hole to the caliper frame after the pads were accurately lined up...


The hole in the fork slider for the brake is 7/16". So I used a 7/16" transfer
punch to mark the center of the fork slider brake lug on the caliper frame,
Then drilled and tapped it for a 7/16" fine thread, and bolted it up with a 1/4"
thick washer as a spacer, as the final caliper support down to the axle will be 1/4".
The two original holes in the caliper frame were 10mm fine, drilled them and
retapped them also to 7/16" fine.

I'm looking for some ss 7/16" fine thread allen head bolts to use on this, the cap screws are ok for now though...

Pulled a piece of 1/4" thick channel out of the scrap pile to cut the final piece.


There is a bit of a problem here though, as the fork slider brake anchor tab
is not in alignment with where the part that fits on the axle, so they will be two
separate pieces that will be aligned and welded back together.


It's gettin' there....
Aloha,
Willy
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Old 02-07-2015, 02:04 PM   #131
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Default Re: '62 Chop, 4th Rebuild in 42 years.....


Rough cut these two pieces for the brake caliper support
from some 1/4" scrap steel I had on the junk pile....
Left plenty of room around the edges to reshape as necessary....

The bottom piece overlaps behind the top piece, as the fit on
the axle is offset 1/4" from the fit at the original brake lug on the fork slider.

Fitted the upper piece to the caliper....

And transfer punched the three holes to get the centers...

Drilled with an 1/8" bit first to center the holes, then with a 7/16" bit....
It bolted up perfectly....

Another view....
The long center bolt will anchor it to the lug on the fork slider....
The chalk mark shows where I have to trim it a bit to get a better fit against the fork slider.
I'll do that a little at a time until I get the fit I want.

Now to cut the hole in the other piece to fit the axle,
fit the two pieces together, and weld them....

Aloha,
Willy

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Last edited by 2Loose; 02-07-2015 at 02:22 PM.
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Old 02-08-2015, 12:10 AM   #132
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Had to keep trimming the bottom of that upper piece until I got a good fit
against the side of the fork slider and the brake lug....


This piece now fits snugly against the side of the fork slider when bolted up solidly....
And there is good alignment with the brake disk....


Looks good from the other side as well....


And the front wheel will still drop out with the caliper in place, a good thing....


Cut the 1-1/4" hole in the lower piece, put it on and aligned the two pieces, overlapping them....
And welded em' up....


Checked em' against my templates, this is working out well....


The other side, this is the side that faces the wheel....


Bolted everything up, and flipped the forks over to the correct side up, and it all looks great !
I still need to do some more grinding and polishing, then some paint, and that bracket is done....



I'm looking for a master cylinder, kinda old style looking, for the handlebars....

Aloha,
Willy
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Old 02-08-2015, 02:22 PM   #133
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Some fabriction going on, have to follow your build...
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Old 02-09-2015, 01:16 PM   #134
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

SG, I'm subscribed to both your build threads.

I have the vin of the Suzuki my front disk brake setup came off of,
went online and found it was a 1985 Madura GV700 V4, found
a caliper rebuild kit for it online and ordered it.

A 700 cc V4? Man, with 175 cc cylinders, with 4 valves per, that
motor must have been a screamer....

Now looking for a master cylinder for it.
Something simple and the older looking the better.
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Old 02-09-2015, 01:51 PM   #135
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I like that you keep chipping away at this. Sometimes it really is only half an hour or so that you can get away to the shop for, and sometimes building up a bike takes a little while.
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Old 02-10-2015, 05:59 AM   #136
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Quote:
Originally Posted by 2Loose View Post
Now looking for a master cylinder for it.
Something simple and the older looking the better.
I like the Honda CB750 master cylinder, it might work for your application.

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Old 02-11-2015, 02:01 AM   #137
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Damn, Willy you're busier than a one armed Paper hanger! Looks great. Love that Honda Master cylinder. Any more info on that? Year, model etc? Capacity?
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Old 02-12-2015, 12:35 PM   #138
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Yeah, I like that honda unit too. Wonder if that would fit on a 1" bar? A lot of those are only 7/8"....


Bought a quart of PPG, JAU Direct Gloss Acrylic Urethane in Torch Red.
Got my gun out and blew some red on the tank and rear fender.
Now we're gettin' back to the old color, I had originally sprayed this color in lacquer,
don't remember how many coats, but there were a bunch, each hand rubbed....

Ya don't wanna breath this stuff, so I did it in my carport, a very light breeze was flowing through
which made it perfect!
Later in the afternoon a little sunlight peeked in through the trees outside and lit up that red paint,
This pic just doesn't do this paint justice !!

The frame is not ready to paint just yet, but I had a little paint left in the gun, so I blew
that last bit on some of the frame tubes just for a look-see....
Yup, that's the color I remember....
I want to smooth out some of those welds before I paint the frame.


Aloha,

Willy

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Last edited by 2Loose; 02-12-2015 at 12:49 PM.
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Old 02-12-2015, 01:18 PM   #139
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

I found this one at an online bizz, www.vintagecb750.com .....



but I suspect it is only available in 7/8", have an inquiry out to them to find out.
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Old 02-12-2015, 01:50 PM   #140
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Default Re: '62 Chop, 4th Rebuild in 42 years.....

Well, as I suspected, it is available for 7/8" handlebars only....
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