Still plugging away, wanting a change from fibre glassing I fitted the spoked front wheel and found that I needed to relieve the back of the calipers a bit to get clearance for the spokes.
That done next was to correctly size the hardware. The cap screws for the discs had to be shortened and also have the underside of the heads turned down to clear the lower caliper adaptor plate bolt. Also had to shortened the nuts holding the bolts.
After that I nickel plated all the bits that had been machined to stop them rusting.
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Next up was a pick up for the speedo, this is being driven of the rear disc bolts. I am using non stock bolts with raised ID on them and thought that the irregular surface would cause problems with the pickup. I machined the heads flat and plated them as well. Not 100% happy with my bracket but it will do for now.
I also bought some bushes for the handlebar mounts (the same parts as an XS 650) so was able to measure and buy the bits to assemble the brake lines.
On track bikes I use AN fittings but this is a road bike and only certain types of line are accepted at inspection luckily there are lots of options, so you buy the parts you need and assemble them.
Pulled the brake calipers apart and was pleasantly surprised that the pistons and seals were all in good shape. Many people use a special tool to remove the blue spots to get the pistons out. I did consider buying the tool but opted for my trusty XS master cylinder and meths method. It was easy to get the first piston out on the front but after that it became harder. I very carefully used compressed air in combination with clamps, old brake pads and fingers to block holes to pop the others. Pretty easy really so if you have these calipers save your money.
In one photo you can see the small amount of metal removed for clearance.
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The calipers have been cleaned and painted. While on the job I polished the stainless cover plates and plated the brake pad holder pins. While fiddling with the wheels I decided to replate the ends of the axles and the nuts.
Next was to sort rear foot pegs, after a rummage round I found some XS ones so sorted out their mounting and pulled them apart for a bit of a refurb.
The clevis pin holes are ovals but can be drilled to 8mm for bigger pins to remove slop so they should be ok. 8mm pins on order.
Still so much to do.
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. I’ve had so many hold ups, one being the engineers I use. Their workshop complex went up in flames and a lot of my stuff was trapped inside for months and I lost a bit of interest at that point. But we’re on the move again now.
