A new dawn (DIY brake mount and CARBON CATACLYSM content)

You may recall my DIY fork-disc-brake mount. Which broke 😮

Well I’m having another go and here’s a sneak peak of the start of the hand-crafted manufacturing process. Note the use of balsa wood and sellotape (the branded stuff, not any cheap copy).

Updates to follow over the next few days…

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IMG_0024[1][/url] by alan cole[/url], on Flickr

I’m with you all the way.

Now could it have possibly broken?

I’m with you all the way.

To the hospital?

Here we go 🙂 :

Will the caliper be front mounted on the fork? If so, why?

Nice to see a quality finished job.
You should be pleased with that.
Tim

Front mounted? Wouldn’t the calliper try to pull itself off the fork leg when you use the brake rather than push itself on?

You’re doomed, the rotor is going in the wrong direction. Apart from that it’s fine 😆 😉

Good job he works in a boik shop 😯

Im not sure if the sellotape will work well and the bit of balsa wood seems unfinished.

But then again, that shouldnt put you off.

Well done for having another go 🙂

You’re mental. In a good way 🙂

front mounted, yes – it seems to me the pull will tension the carbon wrap (to follow) which is how carbon works – rather than try to compress it. Also stops the hhub pulling out of a vertical fork end (important as I use an allen key security skewer).

Might be OK in Lincolnshire….

String actuated brakes. It’s the future.

Well it’s held on OK, now to get the structural stuff done in carbon.

[/url]
IMG_0038[1][/url] by alan cole[/url], on Flickr

Updates to follow over the next few days…

What – that’s not the finished article…??

DrP

That’s the carbon wrap on..

[/url] IMG_0044[1][/url] by alan cole[/url], on Flickr

couple of cable ties round that and you’re good to go… 🙂

Into the autoclave then?

you are not fooling me that is just duck tape

I think I have some carbon wrap then, it’s in with my electrical bits and bobs 😕

whats that suspicious dribbly whitish liquid?

The carbon goes on with epoxy resin (the white stuff)

You then put electrical tape on it to squeeze the epoxy out and keep it all in place. what you see os said tape.

Unveiling in a day or 2. Then probably touching up a bit then finishing, fitting & instant death.

I salute your total refusal to admit defeat, sir, it is admirable. Insane, but admirable. 🙂

whats that suspicious dribbly whitish liquid?

Monkeyjizz

why on the front? In the normal place would have been better. Tension better than compression. If it goes bad then give me a shout and I’ll send you some cured carbon plate to make an IS tab and some UD pre-preg to secure it with.

andyl – on the front is under tension.

oops! 😳

been a long day. In that case carry on….The disc was making me think it was spinning the other way.

I think I remember this from the spoon episode now.

Please tell me you will write your Will before the test ride!

boblo

Into the autoclave then?

Remember to take your oven chips out first, otherwise they taste funny…….

I hope you’ll be mating this to a rotor made out of an old biscuit tin lid and a caliper fashioned from bamboo salad servers. Otherwise I, for one, will feel cheated.

Not looking too bad

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Untitled[/url] by alan cole[/url], on Flickr

Serious question: Under braking the top is under tension the bottom under compression. What stops the balsa spacer being crushed at the bottom? Shouldn’t you have used a non crushable spacer?

Serious answer: the bottom isn’t in compression! I checked!

Another question (sorry).
Is there a reason for placing it on that fork leg when it’s normally on the other one?
Looks good by the way.
I will follow this thread with interest….

is it really worth the effort when these are less than £70 ?

http://www.wiggle.co.uk/kinesis-crosslight-3-alloy-cyclocross-bike-forks/

Al – for a better finish, you should wrap the tape with the sticky side out (but well done for remembering to puncture the tape to let the air/excess resin out!)

cynic-al – Member
Serious answer: the bottom isn’t in compression! I checked!

Puzzled. How can it not be? The top will be pulled ( I.e. in tension) when the brake is applied. This must mean the bottom is in compression as the load is not totally perpendicular to the caliper adaptor. Surely? My bet is the carbon wrap will stop this at first then fail progressively as the brake is used and the balsa will be crushed.

Puzzled. How can it not be? The top will be pulled ( I.e. in tension) when the brake is applied. This must mean the bottom is in compression as the load is not totally perpendicular to the caliper adaptor. Surely?

I’d have thought the bottom will be pulled too, can’t see anything in compression.