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

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  • A new dawn (DIY brake mount and CARBON CATACLYSM content)
  • cynic-al
    Member

    You may recall my DIY fork-disc-brake mount. Which broke ๐Ÿ˜ฎ

    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…


    IMG_0024[1] by alan cole, on Flickr

    ChunkyMTB
    Member

    I’m with you all the way.

    Premier Icon paulosoxo
    Subscriber

    Now could it have possibly broken?

    khani
    Member

    I’m with you all the way.

    To the hospital?

    boblo
    Member

    Here we go ๐Ÿ™‚ :

    bigyinn
    Member

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

    timbur
    Member

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

    khani
    Member

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

    Premier Icon P20
    Subscriber

    You’re doomed, the rotor is going in the wrong direction. Apart from that it’s fine ๐Ÿ˜† ๐Ÿ˜‰

    boblo
    Member

    Good job he works in a boik shop ๐Ÿ˜ฏ

    Trimix
    Member

    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 ๐Ÿ™‚

    simondbarnes
    Member

    You’re mental. In a good way ๐Ÿ™‚

    cynic-al
    Member

    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).

    Premier Icon oldnpastit
    Subscriber

    Might be OK in Lincolnshire….

    IanMunro
    Member

    String actuated brakes. It’s the future.

    cynic-al
    Member

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


    IMG_0038[1] by alan cole, on Flickr

    DrP
    Member

    Updates to follow over the next few days…

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

    DrP

    cynic-al
    Member

    That’s the carbon wrap on..

    IMG_0044[1] by alan cole, on Flickr

    lazybike
    Member

    couple of cable ties round that and you’re good to go… ๐Ÿ™‚

    boblo
    Member

    Into the autoclave then?

    Junkyard
    Member

    you are not fooling me that is just duck tape

    Premier Icon joat
    Subscriber

    I think I have some carbon wrap then, it’s in with my electrical bits and bobs ๐Ÿ˜•

    Premier Icon amedias
    Subscriber

    whats that suspicious dribbly whitish liquid?

    cynic-al
    Member

    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.

    Premier Icon mintimperial
    Subscriber

    I salute your total refusal to admit defeat, sir, it is admirable. Insane, but admirable. ๐Ÿ™‚

    whats that suspicious dribbly whitish liquid?

    Monkeyjizz

    andyl
    Member

    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.

    toys19
    Member

    andyl – on the front is under tension.

    andyl
    Member

    oops! ๐Ÿ˜ณ

    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.

    Premier Icon superdale
    Subscriber

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

    maxtorque
    Member

    boblo

    Into the autoclave then?

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

    Premier Icon Cheezpleez
    Subscriber

    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.

    cynic-al
    Member

    Not looking too bad


    Untitled by alan cole, on Flickr

    boblo
    Member

    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?

    cynic-al
    Member

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

    alanf
    Member

    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….

    b45her
    Member

    is it really worth the effort when these are less than ยฃ70 ?

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

    bristolbiker
    Member

    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!)

    boblo
    Member

    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.

    IanMunro
    Member

    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.

Viewing 40 posts - 1 through 40 (of 149 total)

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