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Mailmans , 77D getting a makeover

Discussion in 'The Garage' started by Mailman, May 5, 2019.

  1. 59Tebo

    59Tebo 59Tebo Top Contributor

    The only problem with the HFT (cheapie) drill press is, even though it's a 5-speed, all the speeds are too damn fast! The bigger the hole, the slower the bit...
    Jim likes this.
  2. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    Maybe a heavy duty light dimmer to slow it down?
    Jim likes this.
  3. Beags64

    Beags64 XS650 Junkie Top Contributor

    Light dimmer decreases the voltage, motors don't like that. Motor controls vary the frequency, not sure if a ceiling fan type control could handle the load
    Jim likes this.
  4. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    According to HF it draws 2.4 amps. Light dimmers don't reduce voltage. They reduce duty cycle. I have had good results reducing speed of lightly loaded motors with light dimmers.
    Jim likes this.
  5. thuban

    thuban Horse Scratcher XS650.com Supporter Top Contributor

    Mailman, I hate ya', just hate ya'! Damn good work! I'm still waiting on a pretty day to paint my tank!
    geedubya, Mailman and Jim like this.
  6. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    HF has everything.... including AC speed controllers. :D

  7. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    HF review for speed controller.
    Screen Shot 2019-11-02 at 7.59.44 PM.jpg
    gggGary and Jim like this.
  8. 59Tebo

    59Tebo 59Tebo Top Contributor

    Yup. I saw that. I might have to take a chance, and get me one of those. If it doesn't work with the drill press, I do have a router I can use it on...
    One way or another, "The Basketcase" is gonna have a drilled front brake rotor...
    geedubya, gggGary and Jim like this.
  9. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    This guy is in Phoenix.:wink2: Your bbbBuddy gggGary.
    millrite e.gif
    Hi all. I am selling my mvn mill. I have the complete mill unassembled. I will sell all for $350. Great buy for someone wanting to rebuild a mill. Contact me at spaquette54@... for pictures and discussion.

    And it wouldn't violate your Two Bike rule!
    Last edited: Nov 3, 2019
  10. GLJ

    GLJ Never go faster than your guardian angle can fly. Top Contributor

    I can see it now. A mill rebuild thread. :woowoo:
    Go for it Mailman.
    MaxPete, Mailman, MrBultaco and 2 others like this.
  11. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    Yeah - go for it Mailman - Laura won't mind.....;)
    GLJ, Mailman, gggGary and 1 other person like this.
  12. azman857

    azman857 '80 XS 650SG Rider XS650.com Supporter Top Contributor

    And I'll be your first customer to mill and drill drill my 3 to 5 discs.
    MrBultaco, Mailman, GLJ and 3 others like this.
  13. geedubya

    geedubya geedubya Top Contributor

    Us green gasket people are sick of you racists..........my green cylinder base gasket just oozes persona, lol

    azman857, MrBultaco, Mailman and 4 others like this.
  14. Mailman

    Mailman Hardly a Guru Top Contributor


    Operation Stop that Squeal!!

    Ok, I got kinda stalled out on this for a while. Here’s where I’m at, the caliper and the caliper carrier have been cleaned and painted with high temp caliper paint. The front disc has been cleaned, surfaced and measured to confirm that everything was in spec. The man from Baraboo has supplied me with a couple of the mysterious and unobtainable brake pad shims. I’ve got a pile of new parts on my bench top and I’m ready to make the magic happen.
    When the shims arrived the condition was pretty rough, they had been well used.

    The shims are metal, but I’m not exactly sure what the coating is, it feels tougher than paint, almost like a thin vinyl.
    However it was in poor condition, so I stripped them and painted them with the same caliper paint that I used to paint the caliper.
    My parts ready to assemble,

    In the plastic bag is another of the factory attempts at stopping brake squeal, inside that chrome clip are a couple little thin squares of thin ( vinyl ? ) It gets mounted in the front location. Normally a caliper would not have both the brake pad shims and that chrome clip replacement. But, I’ve got both and they won’t interfere with each other , so What the heck, I’m throwing them all in.
    Here are some detail shots showing how the shims are installed behind the brake pads. The weird shapes of these things are frankly baffling to me.
    Edit: Please note, in the photo below, the position of the shim is incorrect. It should be flipped over, end for end.
    E248B6A4-69BB-46D1-8A85-8842E4B8A523.jpeg FE402934-693D-4B21-BBFD-2322384A3DCB.jpeg

    And here the new chrome clip installed in the front of the carrier.

    Everything assembled and ready to install. I chose not to apply grease anywhere in this assembly because the last time I did, it wound up in unintended locations and created a real mess.

    And installed back on the forks.

    Next up I will need to hook up my front brake line and bleed the brakes.

    Observation: the brake pads from EBC are pretty thick as it is and the new shims, even though they are very thin, they add additional thickness. Fitting the caliper back on over the disc was a little snug. I will have to see if it drags too much. I’m also curious if my painted shims will still perform as well as the original coating.
    To be continued.........
    Last edited: Nov 12, 2019
    MaxPete, 59Tebo, gggGary and 3 others like this.
  15. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    I don't think the coating will affect anything... was prolly just a powder coating of some sort. I'm guessing the shape is the fix. A brake squeal is nothing more than a high frequency vibration that (comes close to) matching the harmonics of the pads or the rotor. Changing the shape of either changes the harmonics of the vibration and reduces or eliminates the squeal. The shims effectively change the shape of the pads.

    Hows that for goin' all geek on a post... :er:
  16. Mailman

    Mailman Hardly a Guru Top Contributor

    Haha! Well you know I’m a geek at heart. Sounds like a reasonable assessment. I’m very curious to see if this works. At first the resurfaced disc will keep the squeal at bay. It’s usually after things start to glaze that the squeal appears.
    Moabite, Team Junk and Jim like this.
  17. Moabite

    Moabite XS650 Addict Top Contributor

    ...bleeding key too, one little bubble may not make brake feel spongy, but can cause squealing... I make extra long bleeder hose go back into resevoir and use clear tube...just do not spill even a drop on pads or rotor...
    59Tebo, Mailman and Jim like this.
  18. mrtwowheel

    mrtwowheel Honda Etched On Brain Top Contributor

    :popcorn: No change to the pads, not much change to the disc, I'm sitting on the edge of my seat/couch.
    MaxPete, gggGary, Jim and 1 other person like this.
  19. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    Manufacturers originally installed calipers ahead of the tubes. The braking force pulled against the mounting bolts. Fashion, magazines, and a bit of improved weight distribution, moved them behind the tubes, the force now pushes against the mounting bolts AND the push is at an angle, the rotor is offset from mounts. Both those contribute to the possibility of vibration. The angled force is why the odd shim shape, they help counter the tendency of the pads to wear at an angle. If you envision how the stopping force tends to move the pads and shims you'll get the two different shapes. Modern sport bikes get radial caliper mounts to counter this.
  20. Superjet

    Superjet XS650 Guru Top Contributor

    Just my two cents worth on EBC. I used them on my Roadstar and have gone thru a few sets of different models. The HH semi sintered was the best stopping power over the organic ones Bob has installed but at a price to the discs. Wear down the discs easy but not much dust. Last winter I redid my whole brake setup including new stainless lines, rebuilt calipers and new organic pads. Near the same stopping power with a little more dust rather than a chewed up disc. Will continue to use Organic pads. Maybe next go around will try out oem pads on my xs vs the ones I have now. JC
    Last edited: Nov 11, 2019

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