Another Kawasaki Project !
- Thread starter CAT3
- Start date
and 
even though you’re not. 
Been to collect my new titanium front axle this morning so I can get on with making the two front wheel spacers now.
Because the hex heads are flat they look a bit bland now in the cold light of day so I might take them back at some point just to get a recess machined into each face to make them look a bit more pleasing to the eye. But that can be done anytime & it won't stop any progress !
Because the hex heads are flat they look a bit bland now in the cold light of day so I might take them back at some point just to get a recess machined into each face to make them look a bit more pleasing to the eye. But that can be done anytime & it won't stop any progress !
Just made a couple of temporary spacers out of Delrin, (an engineering plastic) to check the widths, wheel is now cock-on central so I'll machine the final versions tomorrow while I'm machining the gear lever support for the ye olde bobber I'm also building.
The next job will be drawing the adaptor brackets up to mount the two from calipers, hopefully once the first one is drawn the other side will just be a "mirror" of that one
Followed by another shit bracket for the ABS wheel speed sensor !
The next job will be drawing the adaptor brackets up to mount the two from calipers, hopefully once the first one is drawn the other side will just be a "mirror" of that one
Followed by another shit bracket for the ABS wheel speed sensor !
Just made a couple of temporary spacers out of Delrin, (an engineering plastic) to check the widths, wheel is now cock-on central so I'll machine the final versions tomorrow while I'm machining the gear lever support for the ye olde bobber I'm also building.
The next job will be drawing the adaptor brackets up to mount the two from calipers, hopefully once the first one is drawn the other side will just be a "mirror" of that one
View attachment 95377
View attachment 95378
Mmmm, smell that formaldehyde
Pot, kettle ......... again !Mmmm, smell that formaldehyde
Keh?Pot, kettle ......... again !
Delrin is a trade name owned by Dupont for their version of Polyoxymethlene (or POM for short) which is also more commonly known as Acetal.
It is a polymer of formaldehyde and gives off formaldehyde gas when heated or machined.
Here's a cut and paste from the tinternet:
Formaldehyde can cause irritation of the eyes, nose, and throat, even at low levels for short periods. Longer exposure or higher doses can cause coughing or choking. Severe exposure can cause death from throat swelling or from chemical burns to the lungs.
Now what did you think I meant
He's referring to your circulatory systemPot, kettle ......... again !
Plausible.I think he breathed rather a lot in perhaps and it sent him doolally
My bolts came yesterday to mount the caliper so I figured today I'd get on with that job.
I thought I'd make up a mock caliper mount today so I could work out dimensions for the final parts & then get my mate to draw them up ready for machining.
It's just gone 10pm now & I've just finished, just shows how plans can go astray. What started out as a simple measure up/do drawing/make template ended up taking all day. My first effort was so far out it was embarrassing when I offered it up to try. It took the rest of the day to work out what I was doing wrong !!
Making parts that have different radius & centres is NOT straightforward !!
Anyway, it's done now
I hope !
Below is my paper cut-out after I'd finally managed to get my dimension correct. I've roughed out the mock mount from a piece of 10mm thick alloy plate so tomorrow I'll file it up & clean it up a bit. Once it's bolted in place I'll be able to do the final dimensions to ensure the caliper runs centrally over the disc. It should also be a "mirror" of the right-hand side so I can try it on that side too. Providing it is a mirror, it should only take my mate a few minutes to draw that side. Once "mirrored" he'll just need to delete the bottom 5mm hole.
The small 5mm hole at the bottom is, hopefully, to mount the ABS wheel speed sensor. Hopefully it will line up & that way I don't have to make a shit bracket that picks up the two axle clamp bolts like Exi did on his Kawasaki !
I thought I'd make up a mock caliper mount today so I could work out dimensions for the final parts & then get my mate to draw them up ready for machining.
It's just gone 10pm now & I've just finished, just shows how plans can go astray. What started out as a simple measure up/do drawing/make template ended up taking all day. My first effort was so far out it was embarrassing when I offered it up to try. It took the rest of the day to work out what I was doing wrong !!
Making parts that have different radius & centres is NOT straightforward !!
Anyway, it's done now
I hope !Below is my paper cut-out after I'd finally managed to get my dimension correct. I've roughed out the mock mount from a piece of 10mm thick alloy plate so tomorrow I'll file it up & clean it up a bit. Once it's bolted in place I'll be able to do the final dimensions to ensure the caliper runs centrally over the disc. It should also be a "mirror" of the right-hand side so I can try it on that side too. Providing it is a mirror, it should only take my mate a few minutes to draw that side. Once "mirrored" he'll just need to delete the bottom 5mm hole.
The small 5mm hole at the bottom is, hopefully, to mount the ABS wheel speed sensor. Hopefully it will line up & that way I don't have to make a shit bracket that picks up the two axle clamp bolts like Exi did on his Kawasaki !
Cleaned the mock caliper adaptor up this morning & tried it for size. Fits perfectly so that was a relief, I didn't fancy making another !! 
I tried it on the right-hand side too & it fits that side too although I did notice the required spacers that would be needed to centralise the caliper over the disc varied between the two sides. The left-hand side would need spacers around 8mm while the right-hand side would be around 3mm. The final adaptors will be machined to suit each side so I won't bee using spacers anyway, but I'll be making some just so I know exactly how thick the adaptors need to be in that area.
The ABS sensor mount seems to work OK too & the cable looks to be plenty long enough to reach the headlight, (where it connects apparently).
Obviously this side's adaptor will not have that lower mount for the ABS sensor.
The difference in required spacers can be seen in the two photos below, this is the left-hand side.
And this is the right-hand side.
When I looked, the caliper mounting boss on the two lower forks legs is in a different position slightly, hence the off-set difference. I did wonder where the difference was because I know the wheel is dead central in the forks/yokes.
The ABS sensor mount should work well too, although the gap is a bit big at the moment !, but a suitable spacer will soon cure that problem. I think is should be around 1mm maximum, but I'll check my workshop manual. I'll also be able to mount a P-clip to the back of that adaptor, which will hold the sensor cable securely & stop it flapping about. I will have to re-position some or all of the cable grommets, but that won't be a problem.
I tried it on the right-hand side too & it fits that side too although I did notice the required spacers that would be needed to centralise the caliper over the disc varied between the two sides. The left-hand side would need spacers around 8mm while the right-hand side would be around 3mm. The final adaptors will be machined to suit each side so I won't bee using spacers anyway, but I'll be making some just so I know exactly how thick the adaptors need to be in that area.
The ABS sensor mount seems to work OK too & the cable looks to be plenty long enough to reach the headlight, (where it connects apparently).
Obviously this side's adaptor will not have that lower mount for the ABS sensor.
The difference in required spacers can be seen in the two photos below, this is the left-hand side.
And this is the right-hand side.
When I looked, the caliper mounting boss on the two lower forks legs is in a different position slightly, hence the off-set difference. I did wonder where the difference was because I know the wheel is dead central in the forks/yokes.
The ABS sensor mount should work well too, although the gap is a bit big at the moment !, but a suitable spacer will soon cure that problem. I think is should be around 1mm maximum, but I'll check my workshop manual. I'll also be able to mount a P-clip to the back of that adaptor, which will hold the sensor cable securely & stop it flapping about. I will have to re-position some or all of the cable grommets, but that won't be a problem.
Collected the 3D prints of the two caliper mounts today & checked they fit. Can't check the wheel/disc/caliper alignment yet as I'm having the wheel spindle altered slightly, so it doesn't look so plain at the two ends. Once I get that back I can check the alignment & all being well, get the final items machined.
They line up with the fork legs & calipers OK though, so I measured those bit correctly at least !!
I'll be using the drilled titanium bolts for the final fix & just need to machine a small spacer to get the correct gap on the ABS/speed sensor at the bottom of the left-hand leg.
They line up with the fork legs & calipers OK though, so I measured those bit correctly at least !!
I'll be using the drilled titanium bolts for the final fix & just need to machine a small spacer to get the correct gap on the ABS/speed sensor at the bottom of the left-hand leg.
The postman came loaded today with presents for both the Métis & RS projects.
The Goodridge hose & fittings came that will hopefully allow me to complete the front brake hose assemblies, providing I've not missed anything !!
At this rate I'll be finished before another well known Kawasaki project !!
Hopefully this weekend I'll be able to get the three lines I need cut to length & sent back for swaging. Then once I get those back I'll be able to cut the hoses to their final lengths & sent back once again for final swaging & pressure testing.
The Goodridge hose & fittings came that will hopefully allow me to complete the front brake hose assemblies, providing I've not missed anything !!
At this rate I'll be finished before another well known Kawasaki project !!
Hopefully this weekend I'll be able to get the three lines I need cut to length & sent back for swaging. Then once I get those back I'll be able to cut the hoses to their final lengths & sent back once again for final swaging & pressure testing.
Did you laser print them firstThe postman came loaded today with presents for both the Métis & RS projects.
The Goodridge hose & fittings came that will hopefully allow me to complete the front brake hose assemblies, providing I've not missed anything !!
At this rate I'll be finished before another well known Kawasaki project !!
View attachment 103797
Hopefully this weekend I'll be able to get the three lines I need cut to length & sent back for swaging. Then once I get those back I'll be able to cut the hoses to their final lengths & sent back once again for final swaging & pressure testing.
No Exi, I just assumed because they had been made by a proper company, that they would fit !!Did you laser print them first
Ever thought about buying an OCC scoot btwNo Exi, I just assumed because they had been made by a proper company, that they would fit !!
A-B-S-O-L-U-T-E-L-Y NOT, overpriced, thrown together, S-H-I-T !!Ever thought about buying an OCC scoot btw
While many may not like my bobber, at least I know it is well put together & I like it for what it is & accept it's foibles !!
If I were paying OCC's sort of asking price I'd be wanting something like this below ............. with change !!
Or this
Calm doon!!!A-B-S-O-L-U-T-E-L-Y NOT, overpriced, thrown together, S-H-I-T !!
While many may not like my bobber, at least I know it is well put together & I like it for what it is & accept it's foibles !!
If I were paying OCC's sort of asking price I'd be wanting something like this below ............. with change !!
View attachment 103821
Or this
View attachment 103822
I just knew that would get to you
at least they build then in two days not 20 years like what you do
They've ridden them all - Vyrus is a Bimota Tesi 2D, they just kept getting betterVyrus is the future, Gibbons obviously hasn't been introduced yet !!
Got my front axle back from the machine shop today, (just having it altered slightly, visually, to look a little less plain) so that I could check the alignment of the brake calipers/discs. Seems to be neigh on perfect so very happy about that & I can go ahead now & get the caliper adaptors machined.
All I'll need to do then is measure up the spacer required to set the ABS sensor gap & then get the front end mock fitted to the bike before I commit to having the new yokes machined.
This is the left-hand side, I'll also fit a P-clip on the adaptor in a suitable position to hold the sensor wire.
The right-hand side is basically a mirror of the left-hand side, but without the sensor mount at the bottom. The only other difference is the caliper off-set, which is a bit bigger on the left-hand side.
All I'll need to do then is measure up the spacer required to set the ABS sensor gap & then get the front end mock fitted to the bike before I commit to having the new yokes machined.
This is the left-hand side, I'll also fit a P-clip on the adaptor in a suitable position to hold the sensor wire.
The right-hand side is basically a mirror of the left-hand side, but without the sensor mount at the bottom. The only other difference is the caliper off-set, which is a bit bigger on the left-hand side.
Picked up the front axle yesterday so at least that little job is out of the way now. I could have done the machining myself, but at the time I needed another job doing, which I couldn't do now I have lost access to a milling machine & I was busy working.
The machining was only for visual effect to be honest, but at least it's done. Just waiting now for some quotes to get the front caliper mounts machined. If you work at Fastec please give someone a dig !!
The machining was only for visual effect to be honest, but at least it's done. Just waiting now for some quotes to get the front caliper mounts machined. If you work at Fastec please give someone a dig !!
Just been to pick my caliper brackets up from the machine shop, getting excited now !!
Left hand side, I just need to thread the hole for the ABS sensor & then get them anodised. After that I can fit the mock-up front end to the bike to check everything lines up & works OK, steering, steering stops, steering lock, etc before getting the new yokes machined.
And the right hand side.
Left hand side, I just need to thread the hole for the ABS sensor & then get them anodised. After that I can fit the mock-up front end to the bike to check everything lines up & works OK, steering, steering stops, steering lock, etc before getting the new yokes machined.
And the right hand side.