The Flandria Makes its Lakeside Debut

Logan Lionz Present: Kitz of Fury Vol. 1

Had a great time.  I saw some old friends and met a few new ones.  I love riding in Chicago.  The stop and go isn't fun, but the reckless abandon is fantastic.

Hydraulic fork conversion cost breakdown

I put it all here:
http://www.mopedarmy.com/forums/read.php?1,3374536

Pinto disc brake and hydraulic fork conversion is done

I'm going to put the pictures here for now. I'll follow up with another post that shows the detailed costs of this project, which turned out to be ~$325. Ouch. I am super happy with the results though. It's a clean install that will seriously out perform the stock setup.

Spacers and Caliper Bracket

I finished modifying the caliper bracket last night. It needed to be moved closer to the rotor in order to achieve full brake pad engagement. That required me to locate, drill, and tap a couple of new mounting holes...and to cut off a corner of the bracket.

I also finished working out my spacer situation. I picked up a selection of them from my local Ace and started cutting them to length. That can be tricky to do with an angle grinder. I'm happy with the end result though.

Now I just need a to pick up a new axle nut from Fastenal tonight and wait for my eBay custom brake hose to show up. I'm almost done.

More machined parts for the pinto fork swap

Today I went to visit a friend of mine with some really nice machining tools. He is the same one that made the hub for the 8 star rotor. In order to keep my M bars, I needed to get rid of the hex portion of the top nut that holds the spring inside the forks. Well, one I got rid of the hex, I really wouldn't have a way to tighten/loosen it. Hmmm....

So, I ordered some set screws to go down inside the top nut. We then machined off the hex in a lathe and drilled a hole in the bottom of the nut. I ran the set screw through the bottom of the nut and welded it in place. I now have a way to put the top nut in place and it is recessed below my M bars.

My Domino throttle showed up today from Treats. I put that on along with a new throttle cable. Now I just need to get the wheel spaced properly, get the caliper bracket modified, and find someone to make me a shorter brake hose.

This process is taking way longer than I expected...

Forks Mounted to the Pinto

Two nights ago with the help of a motocross buddy, I was able to shorten the forks. I took two inches out of the 3-1/4 inches of travel. I really wanted to keep the bike away from having any sort of chopper rake.

Last night I figured out how to deal with the difference between the EBR triple tree clamp and the smaller fork tubes of the SSR Motorsports forks. I used some .5mm shim stock that I heated and bent around the forks to take up the extra space. I thought I would be able to go all the way around with the shim, but it turned out I could only make it about 1/6th of the way. After putting the shim in and clamping it down, I feel confident the EBR clamps will hold the tubes just fine.

Here are a couple of pictures of them on the bike. I was bummed to find out my M bars won't fit. I'll have to switch over to straight bars...one more unplanned expense...damn.