Updgardinr 1100ES Brakes

[Greg B]

Having a nice 4 day weekend, I decided to get started on my brake upgrade.
Here's where I'm at so far.
The rotors have a much larger center hole than the hubs on my wheel. Plus I needed to move the rotor out about 1/8" (or 3mm if you prefer).
Wheel is a 16 incher from an '85 750ES.
So I needed to machine a pair of adapters.

Looking good so far.

I also made a pair of cover plates so I can sandwich the rotor since I will also have to put a six bolt hole pattern to match the wheel.
Four piston Brembos + 310mm rotors.
And yes I still need to make adapters to mount the calipers to the forks.

 

[landshark]

Im in the middle of the same upgrade to my 1000G, im making the caliper brackets at the moment.
I look forward to seeing your results.

 

[posplayr]

What Bike
What rotors
What calipers

Looks like a cool upgrade

 

[landshark]

I guess you are asking Greg, since its his thread and all, but i will tell you what i have.
Same Calipers, mine are off a RS250 Aprillia, so are the rotors i am using, they are different to Gregs, and i am using a radial master cylinder.

What Bike
What rotors
What calipers

Looks like a cool upgrade

 

[posplayr]

I guess you are asking Greg, since its his thread and all, but i will tell you what i have.
Same Calipers, mine are off a RS250 Aprillia, so are the rotors i am using, they are different to Gregs, and i am using a radial master cylinder.

What bike? Are you going to post pics?


I found this............

http://en.wikipedia.org/wiki/Aprilia_RS250

The front brakes of the RS 250 are Brembo dual 298 mm discs with Brembo Oro four-piston calipers. The rear brake is a single 220 mm disc with a Brembo twin-piston caliper.
The front & rear rims are lightweight, 5 spokes, cast aluminum rims are 3.50x17 up front (3.0x17 on the older models) and 4.50x17 out back that require tires of 120/60x17 and 150/60x17, respectively.

 

[Greg B]

The guy I got the rotors from said they were Brembos, but there is no part # by which to verify. But I can't see any reason to doubt him.
The calipers I picked on CL for $75 for the pair. So major score there.
The wheel is from a 750ES, and is going on my '83 GS1100ES. Bye bye 19" front wheel.
Ought to quicken the steering up a bit. Using the whole 750 front end, with clip-ons from a Honda NS400R. Not a lot of difference in weight between the 1100 & 750. Plus the 750 forks are longer & will help make up the difference in wheel sizes.

 

[landshark]

Sorry for the thread Hijack Greg.
Here is a pic, the bike is a 80 GS1000G

I dont think that bracket would hold long though.

What bike? Are you going to post pics?


I found this............

http://en.wikipedia.org/wiki/Aprilia_RS250

 

[jwhelan65]

Is that wood?

 

[landshark]

The guy I got the rotors from said they were Brembos, but there is no part # by wich to verify. But I can't see any reason to doubt him.
The calipers I picked on CL for $75 for the pair. So major score there.
The wheel is from a 750ES, and is going on my '83 GS1100ES. Bye bye 19" front wheel.
Ought to quicken the steering up a bit. Using the whole 750 front end, with clip-ons from a Honda NS400R. Not a lot of difference in weight between the 1100 & 750. Plus the 750 forks are longer & will help make up the difference in wheel sizes.

Sounds like a good project, will it muck up the geometry a bit?

Yes Jwhelan, thats wood i wanted to get a rough idea on shape before i started cutting the alloy.

 

[Greg B]

Since the 750 forks are longer than the 1100 forks, & with the clip-ons mounted above the triple clamps, I end up losing about 1/2" of ride height. That's with Progressive springs with 1.25" long spacer. So I don't think it will be too twitchy. But I do plan on installing a steering damper as well.

 

[Greg B]

A Little Farther Along, More Photos

A Little Farther Along, More Photos

I needed to face the backside of my spacer parallel to the side that the rotor mounts against.
Used the same piece of material to make a fixture to hold the parts on the lathe.

Drilled and countersunk holes, bolted to the fixture. these holes will be opened up later for the rotor bolts. Fixture was faced previously so that the it ran true.

Machining the spacer to size. When finished, they measured dead parallel.

 

[Greg B]

More Photos

More Photos

Setting up the rotors to put the new hole pattern in them.

Indicating the center hole.

Drilling & reaming the new holes.

Back on the bike.

Now I need to design & machine the caliper brackets.
I think I'm going to need to make a nice fork brace also.
After all the parts are done, I'll have them all hard anodized black.
More photos soon. I hope.

 

[rapidray]

NICE bike! I like those ESs! Ray.

 

[Greg B]

Test fitting

Test fitting

A bit overkill, perhaps, but it makes me feel better.

Pretty happy with how they turned out. (At least the second time. Sometimes you gotta start cutting to see how it all goes together)
I neglected to take photos while I was making these, but oh well. And yes, I am well aware that the bleed screw points straight back. but I'll deal with it.

I did make a little video of one of the operations. Sorry, it's a little boring. And sorry for the jerky camera work.
http://www.youtube.com/watch?v=pYG4Kp0YZOI

 

[rapidray]

I like the way your hanger brackets sandwich the fork lugs instead of just bolting through the lugs. It should be much stronger that way? Anything difficult about making them work that way? All the lugs the same & in the same places on both sides or did you have to do any special machining to get them to work this way? Thanks, Ray.

 

[posplayr]

I like the way your hanger brackets sandwich the fork lugs instead of just bolting through the lugs. It should be much stronger that way? Anything difficult about making them work that way? All the lugs the same & in the same places on both sides or did you have to do any special machining to get them to work this way? Thanks, Ray.

That is a very nice brake hanger adapter. Are most of these sandwiched? It certainly should flex less. Is it made of two or three pieces?

 

[rapidray]

It's ONE piece Jim!!! I've seen them & know the story but wanted to get Greg to go into a little more detail on how they are made! That's the ES I sold him in case you didn't know. Ray.

 

[Greg B]

On to the Fork Brace

On to the Fork Brace

A few more fun photos. Enjoy.

I forgot my camera when I machined the main clamp, but this is how they turned out.

Counter boring & drilling the bolt holes.

Sawing the clamp in half.

Mostly done. After I tap the holes, I'll bolt the halves together, set up in the lathe, & finish bore the clamp to fit the fork legs. And machine the groove for the dust caps.
More later.

 

[bluewool]

Greg, That is a fantastic looking upgrade! At first I thought those were gs500e/ katana 600/750 rotors, but it looks like there is too much offset.

 

[gs scott]

Greg,
Super nice work!