Able to stop now(DISK brake setup) - xBhp.com : The Global Indian Biking Community

desideep · 05-23-2009, 09:16 PM

Hey all,
After the conversion of the RX 100 to the RX135 5S the bike was not stopping when I really needed it to. Had got the brakes redone and everything was tried.
we also tried to fit the Pulsar front Wheel set so that we can accommodate the Disk brake and also upgrade to the 17 inch wheels and better tires that are only available in 17 inch (in 18 inch they have the most stupid tires but none is tubeless). With the Pulsar setup the aligntment was not correct too many mods would have been needed to do it to run flawlessly.
We decided to go for a Stunner Wheel set that is a 17 inch. But again non availability of the wheels was a problem. The R15 wheels and brakes were also considered but again did not want to spend as much as my bike on just the wheels tires and brakes.

This is what we ended up doing

Got the wheel and the disk centered from a Machine shop. Got the wheel drilled and the disk was fixed.
The caliper mount was welded to the right fork tube. I know the question is how safe it is.
This was my question. The answer I got was "For some money I just can’t risk some one’s life, don’t worry my friend brakes are more important than the engine."
For now we are running the KBX setup and would be moving to the Yamaha master cylinder and Nissin or a Brembo Caliper according to the availability in next few days.
Maybe also would go for a 17 incher setup.

Sunny · 05-24-2009, 08:44 AM

Topic Approved

ken cool · 05-24-2009, 09:06 AM

Good one there. Nothing like discs to stop a moving vehicle quick!

nirvan · 05-24-2009, 11:36 AM

This looks like an extremely dicey setup to me. What sort of welding is that?

Your best, most cost-effective option is to replace the lower tubes with that of a Pulsar and simply use the Pulsar paraphernalia to make it work. To me, using the alloy wheels isn't as important of getting the job done right.

gsferrari · 05-24-2009, 12:05 PM

That'll be TIG welding and if done correctly the setup can be safely used. In rare cases you'll have a warped fork-leg or in the worst case scenario...it'll snap off under heavy braking.

ken cool · 05-24-2009, 12:09 PM

Quote:

Originally Posted by gsferrari

That'll be TIG welding.

How come you guys know so much! Don't tell me you are a professional welder. They do not come writing English the way you do!

nirvan · 05-24-2009, 12:38 PM

Quote:

Originally Posted by gsferrari

That'll be TIG welding and if done correctly the setup can be safely used. In rare cases you'll have a warped fork-leg or in the worst case scenario...it'll snap off under heavy braking.

Yeah, I was hoping it would be TIG. And the snapping off is exactly what I'd be worried about, TIG or not.

gsferrari · 05-24-2009, 03:30 PM

Quote:

Originally Posted by ken cool

How come you guys know so much! Don't tell me you are a professional welder. They do not come writing English the way you do!

Ken da... these fork legs are aluminum and afaik the only options with aluminum are TIG and Riveting. I think there are also some chemical bonding agents but those are probably not applicable in this case.

Everything I know about bikes is through the people I meet and I havent even begun to scratch the surface.

rossiter · 05-24-2009, 07:18 PM

Quote:

Originally Posted by gsferrari

Ken da... these fork legs are aluminum and afaik the only options with aluminum are TIG and Riveting. I think there are also some chemical bonding agents but those are probably not applicable in this case.

Everything I know about bikes is through the people I meet and I havent even begun to scratch the surface.

Add MIG welding to the list.

That setup looks OK, but nothing stronger/better than riveting when it comes to Aluminium. There's a reason even the aircraft industry rivets aluminium parts together

ken cool · 05-25-2009, 08:56 AM

Quote:

Originally Posted by gsferrari

and I havent even begun to scratch the surface.

Oh my oh my!

Quote:

Originally Posted by rossiter

Add MIG welding to the list.

What's MIG now?

Quote:

Originally Posted by nirvan

TIG.

Tungsten Inert Gas! Thanks.

05-23-2009, 09:16 PM	#1 (permalink)
desideep Oh FCUK!! Join Date: Jun 2004 Location: PB03,DL Posts: 755	Able to stop now(DISK brake setup) Hey all, After the conversion of the RX 100 to the RX135 5S the bike was not stopping when I really needed it to. Had got the brakes redone and everything was tried. we also tried to fit the Pulsar front Wheel set so that we can accommodate the Disk brake and also upgrade to the 17 inch wheels and better tires that are only available in 17 inch (in 18 inch they have the most stupid tires but none is tubeless). With the Pulsar setup the aligntment was not correct too many mods would have been needed to do it to run flawlessly. We decided to go for a Stunner Wheel set that is a 17 inch. But again non availability of the wheels was a problem. The R15 wheels and brakes were also considered but again did not want to spend as much as my bike on just the wheels tires and brakes. This is what we ended up doing Got the wheel and the disk centered from a Machine shop. Got the wheel drilled and the disk was fixed. The caliper mount was welded to the right fork tube. I know the question is how safe it is. This was my question. The answer I got was "For some money I just can’t risk some one’s life, don’t worry my friend brakes are more important than the engine." For now we are running the KBX setup and would be moving to the Yamaha master cylinder and Nissin or a Brembo Caliper according to the availability in next few days. Maybe also would go for a 17 incher setup. __________________ 1993 YAMAHA RX100 \| 1977 RE Bullet 350 STD \| 2008 HH CBZ \| 1997 LML NVSpl \| 2009 Suncross Proceed www.desideep.blogspot.com

05-24-2009, 08:44 AM	#2 (permalink)
Sunny SlowMotionInfinity Join Date: Apr 2002 Location: Delhi Posts: 7,292	Topic Approved __________________ Join xBhp On

05-24-2009, 09:06 AM	#3 (permalink)
ken cool Super Moderator Join Date: Sep 2005 Location: New Delhi Posts: 4,677	Good one there. Nothing like discs to stop a moving vehicle quick! __________________ The Wheel was a great invention; Two Wheels with a Motor in between was even better! BMW Motorrad Days 2011 Xbhp's Indo-French Kashmir-Ladakh Tour

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05-24-2009, 11:36 AM	#4 (permalink)
nirvan Senior Member Join Date: Oct 2008 Location: Secunderabad Posts: 221	This looks like an extremely dicey setup to me. What sort of welding is that? Your best, most cost-effective option is to replace the lower tubes with that of a Pulsar and simply use the Pulsar paraphernalia to make it work. To me, using the alloy wheels isn't as important of getting the job done right.

05-24-2009, 12:05 PM	#5 (permalink)
gsferrari Poser Killer Join Date: Sep 2008 Location: Bangalore, India Posts: 693	That'll be TIG welding and if done correctly the setup can be safely used. In rare cases you'll have a warped fork-leg or in the worst case scenario...it'll snap off under heavy braking.

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