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  1. #1
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    Default Workin on my '62

    Been working on my '62 FL for awhile now. A long bike I've had since 1968.
    Ran it for years with no front brake, time to put one on, but severely narrowed
    forks don't leave a lot of room. Have a '85 Suzuki front disk and caliper, so machined
    a carrier to fit that disk onto the front 21" w/ a star hub and it fits between that narrowed front end
    quite nicely.

    Put the front forks together, put the wheel and brake rotor on,
    and propped up the axle so the wheel can spin....


    Here you can see how tight this space is, 1"....
    I got that rotor right where I want it !
    AND, it spins true, no wobble at all....


    The caliper looks good on top of the rotor....


    Maybe a little further back, almost touching the fork leg....


    Or maybe it should go under the fork leg ??
    It looks like the mounting bracket would be smaller and fit better in this location....


    Whichever way I go, I now need to fab a bracket to mount that caliper.

    I have kept a personal web page on this build, a lot of pix and info there, please take a look if you are interested.

    LINK to Willy's '62 FL pages...

    Aloha from Maui
    2Loose Willy
    Last edited by 2Loose; 01-31-2015 at 6:44 PM.

  2. #2
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    ..... Suzuki, Huh ......

    What I'm going to suggest is perhaps a little cleaner look....

    Click image for larger version. 

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    Click image for larger version. 

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    Super small sallow back Jay Brake solid mount two piston calipers....
    Hub is late Harley dual flange...
    Last edited by Dragstews; 01-31-2015 at 7:09 PM.

  3. #3
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    A year or so ago I did a complete tear down on this bike, it's been parked since about 1990.
    The motor is a stock '74 inch, warmed up a little, now freshly rebuilt, also the tranny and the
    wheels and front forks.

    When I mocked it up to see what else needed to be moved, cut off, or welded back onto
    the frame, it looked like this:

    Everything you see there was on the bike before, except the frame and gas tank,
    they've been sitting in my parts shed for a long time. The frame is a Denver's frame
    I've had for about 30 years.


    Pulled it apart again and sand blasted everything needing it, Ospho etched them and primered them.
    Final paint will be GM Torche Red, which is what it had before.

    Only the frame, tank and rear fender are for the bike, the other parts are for one of my trucks.

    Aloha,
    Willy
    Last edited by 2Loose; 02-01-2015 at 4:28 PM.

  4. #4
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    Quote Originally Posted by Dragstews View Post
    ..... Suzuki, Huh ......

    What I'm going to suggest is perhaps a little cleaner look....

    Click image for larger version. 

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ID:	56147
    Hiya Jesse,
    yeah, that is a nice, clean look....

  5. #5
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    Quote Originally Posted by 2Loose View Post
    Hiya Jesse,
    Aloha Willy .....
    Last edited by Dragstews; 01-31-2015 at 7:15 PM.

  6. #6
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    Great project, would love to see you finish it.

  7. #7
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    Quote Originally Posted by Shayski View Post
    Great project, would love to see you finish it.
    I would like to see more progress on the Supercharged bike....
    That's going to be one Kick-Ass Cycle....

  8. #8
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    Ha!
    Tell my wife to quit adding so many things to my "honey-do" list !!!

  9. #9
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    Been really busy, but found a little time today to cut some cardboard....


    It fits in there really well, and I have the caliper's frame located where I can drill and tap for a bolt from the fork slider's brake lug directly into the frame:


    Now to make this bracket out of 1/4" steel. Wish I had some stainless to do this with.
    Willy

  10. #10
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    Glad to see you'll over here......... Your bikes looking real nice.....

  11. #11
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    Thanks Tat...
    Just wish I could get up more energy to work on 'em like I usta, bein' in my 70's has definitely slowed me down.
    Plus my retired school teacher wife's "honeydoo list" always seems endless....

  12. #12
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    The first step is to get the frame for the caliper correctly located,
    and drill and tap a hole in it for the anchor bolt on the fork slider.


    Decided I needed to be able to more accurately align the pads with the rotor, so I
    pulled off the caliper but left the pads loaded in the frame, transfer punched the center of
    the fork slider hole to the caliper frame after the pads were accurately lined up...


    The hole in the fork slider for the brake is 7/16". So I used a 7/16" transfer
    punch to mark the center of the fork slider brake lug on the caliper frame,
    Then drilled and tapped it for a 7/16" fine thread, and bolted it up with a 1/4"
    thick washer as a spacer, as the final caliper support down to the axle will be 1/4".
    The two original holes in the caliper frame were 10mm fine, drilled them and
    retapped them also to 7/16" fine.

    I'm looking for some ss 7/16" fine thread allen head bolts to use on this, the cap screws are ok for now though...

    Pulled a piece of 1/4" thick channel out of the scrap pile to cut the final piece.


    There is a bit of a problem here though, as the fork slider brake anchor tab
    is not in alignment with where the part that fits on the axle, so they will be two
    separate pieces that will be aligned and welded back together.


    It's gettin' there....
    Aloha,
    Willy

  13. #13
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    Quote Originally Posted by 2Loose View Post
    Thanks Tat...
    Just wish I could get up more energy to work on 'em like I usta, bein' in my 70's has definitely slowed me down.
    Plus my retired school teacher wife's "honeydoo list" always seems endless....

    Man I wish we lived closer I'd be glad to help all I could.....

  14. #14
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    Rough cut these two pieces for the brake caliper support
    from some 1/4" scrap steel I had on the junk pile....
    Left plenty of room around the edges to reshape as necessary....


    The bottom piece overlaps behind the top piece, as the fit on
    the axle is offset 1/4" from the fit at the original brake lug on the fork slider.



    Fitted the upper piece to the caliper....


    And transfer punched the three holes to get the centers...


    Drilled with an 1/8" bit first to center the holes, then with a 7/16" bit....
    It bolted up perfectly....


    Another view....
    The long center bolt will anchor it to the lug on the fork slider....

    The chalk mark shows where I have to trim it a bit to get a better fit against the fork slider.
    I'll do that a little at a time until I get the fit I want.


    Now to cut the hole in the other piece to fit the axle,
    fit the two pieces together, and weld them....

    Aloha,
    Willy

    LINK to other pages on my site for the '62

  15. #15
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    Had to keep trimming the bottom of that upper piece until I got a good fit
    against the side of the fork slider and the brake lug....


    This piece now fits snugly against the side of the fork slider when bolted up solidly....
    And there is good alignment with the brake disk....


    Looks good from the other side as well....


    And the front wheel will still drop out with the caliper in place, a good thing....


    Cut the 1-1/4" hole in the lower piece, put it on and aligned the two pieces, overlapping them....
    And welded em' up....


    Checked em' against my templates, this is working out well....


    The other side, this is the side that faces the wheel....


    Bolted everything up, and flipped the forks over to the correct side up, and it all looks great !
    I still need to do some more grinding and polishing, then some paint, and that bracket is done....



    I'm looking for a master cylinder, kinda old style looking, for the handlebars....

    Aloha,
    Willy

  16. #16
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    I have the vin of the Suzuki my front disk brake setup came off of,
    went online and found it was a 1985 Madura GV700 V4, found
    a caliper rebuild kit for it online and ordered it.

    A 700 cc V4? Man, with 175 cc cylinders, with 4 valves per, that
    motor must have been a screamer....

    Now looking for a master cylinder for the front.
    Something simple and the older looking the better.

  17. #17

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    I started reading your other build links, even the 4door gasser, and couldnt stop until I finished them all- good reads

  18. #18
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    The gasser's been turned into a daily driver, I'm just not competitive at the track gear jammin' against those powerglides and computer controlled motors.


    Bought a quart of PPG, JAU Direct Gloss Acrylic Urethane in Torch Red.
    Got my gun out and blew some red on the tank and rear fender.
    Now we're gettin' back to the old color, I had originally sprayed this color in lacquer,
    don't remember how many coats, but there were a bunch, each hand rubbed....


    Ya don't wanna breath this stuff, so I did it in my carport, a very light breeze was flowing through
    which made it perfect!
    Later in the afternoon a little sunlight peeked in through the trees outside and lit up that red paint,
    This pic just doesn't do this paint justice !!


    The frame is not ready to paint just yet, but I had a little paint left in the gun, so I blew
    that last bit on some of the frame tubes just for a look-see....
    Yup, that's the color I remember....

    I want to smooth out some of those welds before I paint the frame.

    Aloha,
    Willy

    Home Page
    Last edited by 2Loose; 02-12-2015 at 12:50 PM.

  19. #19
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    These nice handlebar controls for the Suzuki disk brake I put on the front wheel showed up today.
    Found this pair of early Honda cb750 controls, 5/8" piston bore, perfect for a single caliper disk setup....

    I like the round style brake fluid reservoir better than the rectangular ones seen around lately,
    and this set included the matching clutch lever....



    The only problem is that these are for a 7/8" handlebar, I can modify the handlebars to have a short section
    of 7/8" plug on each side where these will be mounted, or looking at them it looks like there is
    enough meat in the side of the clamp next to the levers to do an offset bore, so that most of the
    1/8" of metal removed would be against the side where the levers are.
    It doesn't look like it would weaken it at all....




    I might not be able to do that on the master cylinder though, it depends on how close an 1/8"
    cut might get to the internal fluid channels. Need to check that out. There's a lot of "meat' here
    though, maybe just take a 1/16" all around.




    I'll fit it to a piece of 7/8" bar first to see how the gap at the screws looks...

    Aloha,
    Willy
    Last edited by 2Loose; 02-19-2015 at 8:20 PM.

  20. #20
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    Found some time to work on this bike a little, have a different clutch control I like better than the first one I had, and it's for a 1" bar:


    It's got an electrical switch built in, not sure what that's supposed to be for....


    Got a 1" unibit, so I still need to bore out the Honda master cylinder bar mount, but there's a lot of "meat" there, it will be no problem....

    Am also thinking of changing out the handle on the Honda master cylinder using this one, if I can get it to fit....


    Not a very good pic, but this pressure actuated switch fits into the hydraulic fitting on the master cylinder to activate the brake light...


    Meanwhile I still have not gotten the frame ready to paint. Weather's been horrible here, high winds and lots of rain, and my paint booth needs good weather, as it is partially open to the weather....

    Aloha,
    Willy


    More Pix Here
    Last edited by 2Loose; 03-12-2015 at 10:38 AM.

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