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#556157 - 08/01/14 9:23 pm Re: T140 cafe project, cont. [Re: Pete Suchawreck]  
Joined: Jul 2006
Posts: 1,082
J. Charles Smith Offline
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J. Charles Smith  Offline
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Westminster, MD, USA
Originally Posted By: Pete Suchawreck
Great project Charles! Can you show close ups of the front brake ass'y? I may go with a disc at some point too on my Betor front end.
Very nice detail work.


Hi Pete. I don't know if all this will be of any help on your Betor set-up, but maybe. As I mentioned, my engineer/machinist friend Paul and I worked up a combination front fork brace and disc brake caliper mount. The forks are 35mm road race Ceriani legs in 180mm MX triples; the brake is a Performance Machine 4-piston caliper and 330mm disc. Our fork brace will be of this general style (Cerianis on a dry frame).

My original design mounted the caliper ahead of the forks to preclude bending forces on the necessarily long caliper arm. To safely mount the caliper behind the leg would require a (rare and expensive) double lug left Ceriani fork leg. So Paul, in his typically generous and enthusiastic fashion, offered to fabricate a clamp-on fork lug along with the rest of the machine work! So this is our final 3D design with the disc.

And here is a 3/4 view of just the brace. The dimensions are accurate.

So far, Paul has fabricated the lug and the 1/2" thick cross brace for between the 5/16" side plates. Photos to follow.

#556172 - 08/01/14 11:59 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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J. Charles Smith Offline
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J. Charles Smith  Offline
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Westminster, MD, USA
Paul has a terrific basement workshop that's cozy through Minnesota's harsh winters and a cool hangout this time of year. Here is a mill with the barely-begun fork lug clamped to its table.

There was a LOT of machining to get to this stage, with a lot more yet to go.

Paul had drilled and tapped the 4 bolt holes before any shaping of the bare billet began.

Machining the center hole. The clamp-on lug will be cut into two pieces after the basic shaping is done.

#556175 - 08/02/14 12:12 am Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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J. Charles Smith Offline
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J. Charles Smith  Offline
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Westminster, MD, USA
The smaller piece will bolt up to the left side plate of the fork brace.



With some hand finishing, I think it will look quite nice ... for a fork lug, I mean.

The cross brace, which bolts up with eight 6mm button head SS bolts, will be machined to the exact width after the brace is assembled and measured on the forks.

#556199 - 08/02/14 8:09 am Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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Pete Suchawreck Offline
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Western NY
That is a great idea Charles! Nice work! I could make a version of that using a fork brace too. I have no lugs on the forks to mount to so something well bolted to the forks could work well. Thanks for showing me.

#563691 - 09/17/14 4:35 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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J. Charles Smith Offline
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J. Charles Smith  Offline
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Westminster, MD, USA
Paul emailed a bunch more photos of progress on the fork brace, so I figured I'd post a few. The 1st photo is of my PM disc bolted to Paul's XS650 Yamaha wheel. The 2nd shot is of my front wheel - XS650 hub, 8/9 SS spokes, Sun rim powder-coated to match the frame.


The left side plate with holes and half-moon for added lug.

Rough 5/16" 6061 plate on wheel.

Left side plate with 1/2" thick cross brace.

Machining clearance hole in right side plate. "Clearance sweeps" will be machined above the holes in the side plates for the fork gaiters.


The left side plate will be drilled and machined to match the stock PM caliper spacer. The load paths go through the 4 fork lug holes.

And finally, the still-rough brake side plate with the disc.

#564521 - 09/22/14 9:23 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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old mule Offline
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Chihuahuan Desert
Very nice...a lot of real good British bikes come out of Minnesota workshops...must be the winters.

#564641 - 09/23/14 5:19 pm Re: T140 cafe project, cont. [Re: old mule]  
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Pete Suchawreck Offline
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Pete Suchawreck  Offline
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Western NY
WOW! That's gonna give you some stopping power. Excellent project. I'm going to have to add all the brackets for mounting the calipers. Clever doubling as a fork brace.

#571326 - 11/09/14 10:10 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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J. Charles Smith Offline
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Westminster, MD, USA
The machining of the "Brace 'n Brake" is pretty much finished. The exact width of the cross brace will be measured here when the rest of the components arrive from Paul's place in Minnesota. The "clearance sweeps" in the side plates are for fork gaiters. Paul has tightened the clearances where the bolt-on lug circles the fork leg to a maximum of .001". O'boy, more stuff to polish!



Last edited by J. Charles Smith; 11/09/14 10:21 pm.
#571378 - 11/10/14 8:35 am Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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Pete Suchawreck Offline
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Pete Suchawreck  Offline
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Western NY
beautiful job Charles! Well designed. Got me thinking...appreciate the inspiration! Currently building a better seat for my T140 so it'll be during the winter before I get that far.

#571432 - 11/10/14 2:19 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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J. Charles Smith Offline
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J. Charles Smith  Offline
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Westminster, MD, USA
Thanks, Pete. Please post some shots of your project as it progresses!

#611690 - 08/05/15 11:43 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
Joined: Dec 2013
Posts: 3,251
kevin roberts Online content
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kevin roberts  Online Content

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Joined: Dec 2013
Posts: 3,251
ohio, usa
hey bud, you're over your pm limit. i can't nag you about your beautiful machine.

what's happening with this?

enquiring minds want to know.


Into the distance a ribbon of black
Stretched to the point of no turning back
A flight of fancy on a windswept field
Standing alone my senses reeled
A fatal attraction is holding me fast how
How can I escape this irresistible grasp?
#611693 - 08/06/15 12:12 am Re: T140 cafe project, cont. [Re: J. Charles Smith]  
Joined: May 2015
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Zombie Offline
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Zombie  Offline
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Posts: 1,459
Florida PanHandle
Immaculate shop, new machines, great lighting, CAD designs, fantastic ideas, exceptional execution... I don't think this is real. It's a joke being played by a Unicorn drinking Single Malt, and laughing.

Has to Be!

#611742 - 08/06/15 11:34 am Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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J. Charles Smith Offline
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J. Charles Smith  Offline
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Posts: 1,082
Westminster, MD, USA
Thanks for the encouraging words, and I wish I could say I've made meaningful progress, but I've actually been in another down time. There is light at the end of the tunnel, though, once I get these #@^*%! house projects done!

#611888 - 08/07/15 3:51 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
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Zombie Offline
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Zombie  Offline
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Florida PanHandle
House projects... right!

#612139 - 08/09/15 2:56 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
Joined: Jul 2006
Posts: 1,082
J. Charles Smith Offline
BritBike Forum member
J. Charles Smith  Offline
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Posts: 1,082
Westminster, MD, USA
Now we'll retain an image of a single-malt sipping unicorn in our heads forevermore. Talk about evil conspiracies ...

#612145 - 08/09/15 3:26 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
Joined: Dec 2013
Posts: 3,251
kevin roberts Online content
BritBike Forum member
kevin roberts  Online Content

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Joined: Dec 2013
Posts: 3,251
ohio, usa
hurry up with that household stuff and move on to what's really important.

i've been watching this machine for ages. it's an exercise in mechanical beauty


Into the distance a ribbon of black
Stretched to the point of no turning back
A flight of fancy on a windswept field
Standing alone my senses reeled
A fatal attraction is holding me fast how
How can I escape this irresistible grasp?
#614715 - 08/27/15 3:20 pm Re: T140 cafe project, cont. [Re: J. Charles Smith]  
Joined: Jan 2012
Posts: 123
lilo Offline
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lilo  Offline
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Posts: 123
england
Love it.
Keep up the good work.

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