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Discussion Starter · #1 · (Edited)
Can anyone out there help? I have a W & W springer disc brake set up and I am using an early Harley, '72 thru '81, master cylinder, lever and switch gear. It doesn't work 'cos the bore on the master cylinder is 3/4" and the caliper requires 5/8" or smaller. Course I didn't know all this when I bought the controls 'natch. Does anyone know a clever trick to get this all to work or am I going to have to bite the bullet and buy the handlebar stuff all over? then maybe I could get out and ride it!
 

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Matt D said:
Can anyone out there help? I have a W & W springer disc brake set up and I am using an early Harley, '72 thru '81, master cylinder, lever and switch gear. It doesn't work 'cos the bore on the master cylinder is 3/4" and the caliper requires 5/8" or smaller. Course I didn't know all this when I bought the controls 'natch. Does anyone know a clever trick to get this all to work or am I going to have to bite the bullet and by the handlebar stuff all over? then maybe I could get out and ride it!
You can get a sleeve made up and put inside your master cylinder to reduce it's diameter to 5/8". Then you can either turn your piston down to suit or pick up one that's made for 5/8" bore.

Scotty
 

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I thought this might prove helpful - a chart to help with master to brake cylinder ratios. Unless you have access to a lathe and lots of free time, there's no clever trick.

http://www.vintagebrake.com/mastercylinder.htm

Matt D said:
Can anyone out there help? I have a W & W springer disc brake set up and I am using an early Harley, '72 thru '81, master cylinder, lever and switch gear. It doesn't work 'cos the bore on the master cylinder is 3/4" and the caliper requires 5/8" or smaller. Course I didn't know all this when I bought the controls 'natch. Does anyone know a clever trick to get this all to work or am I going to have to bite the bullet and by the handlebar stuff all over? then maybe I could get out and ride it!
 

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Discussion Starter · #4 ·
Thanks guys, I have access to a lathe but not the skills to turn up a sleeve and new piston but I'm gonna have a go, as an alternative does anyone know a company making sort of old style controls that would do the job? everything I have seen is a bit to billet looking for my tastes.
 

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Matt D said:
Thanks guys, I have access to a lathe but not the skills to turn up a sleeve and new piston but I'm gonna have a go, as an alternative does anyone know a company making sort of old style controls that would do the job? everything I have seen is a bit to billet looking for my tastes.
I don't know what size m/c piston you need, but early Honda master cylinders look pretty cool & vintage, and can be had cheap. Some careful work with a dremel tool will help them fit a 1" bar. That ugly cap will polish up nicely.

 

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Matt my friend! I used a small Grimeca on that BeeBob softail I did about 2-3 years ago..the lever that came with it was one of those high-tech black racey versions..I cutted a bar out of a billet aluminum plate, then a grinder, hacksaw, file, sandpaper and polishing paste came into the game..so finally the lever matched my left 60's H-D clutch lever..
 

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Here's an Italian remote master cylinder... They also have the weld on tabs for your bar so you can use (their) Bicycle style levers... Probably not the cheapest sollution...:D

www.kustomtech.it

(check out also their worldknown finned rear drum)
 

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Matt D said:
... It doesn't work 'cos the bore on the master cylinder is 3/4" and the caliper requires 5/8" or smaller...
so help educate me then, why would this setup "not work" .... seems to my simple mind it's better this way than having a Smaller master than "required"... a larger master means more pressure to the brake, right, so would'nt it "work" better ??

be gentle, my friends say that, to me, "hi-tech" is electric start.....

.

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no, it means you pump more fluid per unit of lever travel, which equates to a reduced mechanical advantage. it will still stop you fine, you just have a heavier brake lever to contend with. i'm running the same setup on the flh with the stock master and the tokico caliper.

fab kevin has 5/8" masters for 1" bars, btw
 
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