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Thread: Roadstar Bobber

  1. #201
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    Quote Originally Posted by hillcat View Post
    By how much?
    If it's just barely, I have heard of people shaving the back of the caliper.
    Some being thicker than others.
    Hillcat that would be very scary! Grind through to the inside. Grind off the heads of bolts. Nope.

  2. #202
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    If you have a junk caliper you could grind that to fit then saw it in two at the grind area and know how much metal you have to work with.

    A very useful Air Force habit I kept was to take apart/destroy parts which were "red tagged" as not repairable to see how they were put together.

    BTW if you buy/accumulate longer spacers than you expect to need they are easy to shorten with a zip disc then file to square. As a welder ya know how much metal files can move! If you need spacer stock your machine shop could quickly drill some pieces of round bar you could slice to length as needed.

  3. #203
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    The spacer I am having machined looks like this.
    This is the brake disc side.
    Click image for larger version. 

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    and the other side, the wheel side.
    Click image for larger version. 

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    This second side will be 2.4" NOT 2" NOT 2-1/4"
    The bolt holes will be 5/16 NOT 3/8"

    The thickness of the spacer will be 3/8"

    When I get this part. I can finally put my wheel and brake back on the motorcycle and the wheel will be in the center of the forks and the brake caliper will not rub on the spokes! Then I can put the brake line on and stat to finish the controls.
    Boom!
    Last edited by Luky; 04-12-2019 at 9:47 AM.

  4. #204
    Arthurhart
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    Wow, Great thread.

  5. #205
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    Quote Originally Posted by Arthurhart View Post
    Wow, Great thread.
    Thanks Arthurhart!

  6. #206
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    OK....Moving forward again.

    Today I got the special spacer that was machined by Metal works Precision Machine& Tool in Tucson.
    They were on the Eastside of Tucson instead of along the Freeway like most metal businesses.
    Good for me so I do not have to drive 23 miles to get help.

    So I was able to assemble the front wheel so that the caliper does not rub on the spokes, and the wheel
    is centered in the front forks. Very important.
    So it is a 77-83 Sportster front wheel made for 2 10" front discs.
    It was advertised and sold as a 1984-99 Sportster wheel.
    I have a 11.5 Inch disc mounted on a special spacer on the L/H side
    that mounts on a 2.4 inch hub mount and the spacer accepts a 2" or 2-1/4" disc mount hole. A standard HD style brake disc can be replaced .
    It is a DNA Caliper mount with a Ultima 4 piston brake caliper.

    Some photos.
    Click image for larger version. 

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    It is a 21" x 2.15 Wheel which has a 27.5" OD and uses
    a 2240:60 ratio speedometer drive.
    Click image for larger version. 

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    The speedometer drive fit up without any problems.
    Click image for larger version. 

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    Last edited by Luky; 04-23-2019 at 8:49 AM.

  7. #207
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    Boom! Took some doing but ya got it and that brake assembly is lookin' good. After seeing the brake side, the speedo drive side looks kinda bare - maybe it needs a little hubcap to fill those empty holes...

  8. #208
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    TriNortchopz,

    Thanks for the interest, it has been a while since the last post.
    I have some special button head chrome bolts for those holes on the right side. Should help.
    I saved them from the left side that required longer bolts because of the 3/8 thick spacer.

    Photo of the whole bike now.
    Click image for larger version. 

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    Click on photo for a larger photo.
    Last edited by Luky; 04-23-2019 at 9:32 AM.

  9. #209
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    Damn Luky, this is really a nice clean tight build. Great job can't wait to see it run!

  10. #210
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    Quote Originally Posted by DoomBuggy View Post
    Damn Luky, this is really a nice clean tight build. Great job can't wait to see it run!
    Thanks for the interest Doombuggy. Still a few things to finish though.
    I will post changes.

  11. #211
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    Oh yes-looking forward to them!

  12. #212
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    Yes, we are all looking forward to seeing some YouTube burnouts and wheelies.
    Remember... safety third.

  13. #213
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    Quote Originally Posted by hillcat View Post
    Yes, we are all looking forward to seeing some YouTube burnouts and wheelies.
    Remember... safety third.
    You can sit down now.Lol

  14. #214
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    Drilled and safety wired cylinder exhaust nuts.
    Tomorrow I get some parts.
    Click image for larger version. 

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    Click on photos for a larger image.

  15. #215
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    A nice touch.
    Did you drill through the exhaust studs?

  16. #216
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    Quote Originally Posted by hillcat View Post
    A nice touch.
    Did you drill through the exhaust studs?
    No, I did not drill through the exhaust studs.
    I removed the nuts and drilled them in my vise.
    I would not want to damage the exhaust studs.

  17. #217
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    I received the front brake master cylinder with lever. Used.
    I rebuilt it and cleaned it all.
    I also got the clutch lever and perch. Had to order a new clutch
    lever because the bushing hole was worn out and loose.
    The seller did not mention this on Ebay.

    I got the main relay for clutch, fuel pump, and ignition. I may not have needed it at all.
    On my last build I went through all of this already but did not make any notes. Dumb.

    Today I bled the rear brake master. My wife helped me.
    I encountered no problems. It was a GMA master cylinder.

  18. #218
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    The front master cylinder still not good enough. I finally decided to just buy a brand new one. EDIT: I am getting the Master cyl. from Yamaha.
    The rebuilt master for the front brakes would just not bleed properly. Not enough lever.
    It worked but just not good enough. It would take most of the travel of the lever to get hard.

    I just keep having set backs. Bummer.
    Click image for larger version. 

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    Just sitting now.
    Waiting for the new front master cylinder.
    I did get the ignition switch installed. Just two wires.
    Click image for larger version. 

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    Click on photo for larger image.
    Last edited by Luky; 05-10-2019 at 8:55 AM.

  19. #219
    NancyReeves
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    And what will it be finally?

  20. #220
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    Hey Luky,

    I mounted my switch back behind the coil, but open like yours. What I did do was add a couple of pieces of shrink wrap to waterproof the back end of it. Also makes it a little bit harder to hotwire, not that these are hard to hotwire if someone really wants to.

    I had one bike crap out on me in the rain about 400 miles from home and since then have become a believer in trying to prevent it whenever possible.

    Other then that I really like this build a lot.

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