Updgardinr 1100ES Brakes

[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

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!

[jwhelan65]

Man, that is some nice work

[Greg B]

Thanks everyone
Now, some more photos.......

First I bolted the two halves together & gripped them in the lathe.

Boring the ID.

Internal groove.

Taa Daa!

Next I machined a spud to flip the parts & machine the second side.



Dust seal groove.

There you have it. Clamps for the fork brace.


Now I'm in the process of designing the cross bar that ties them together. Got a few ideas already, just need to make it look good, as well as functional.

[Nessism]

Thanks everyone

Now I'm in the process of designing the cross bar that ties them together. Got a few ideas already, just need to make it look good, as well as functional.

Don't skimp on the thickness of the crossbar Greg. I made a fork brace before and there was a noticeable reduction in stiffness after I thinned down my crossbar to remove some weight.

[Cassius086]

Note to self: GregB is the guy you want to design a fork brace for your GS

Nicely done, Greg!

[Greg B]

Note to self: GregB is the guy you want to design a fork brace for your GS

Nicely done, Greg!

Oh no. I can only show how to make a fork brace for three times what it costs to buy!

[Greg B]

It's only been about 7 months

Done!!! (except for polish & anodize)













I'm not sure though. Looks kind of bulky & overbearing. Maybe because I don't have the fender mounted?
Any thoughts, critiques?

[rapidray]

Looks flimsy & home made. Better just give it to me & buy yourself a good one. Ray.

[TheCafeKid]

Not that I'm questioning your skills or the strength of the brace you made, but why, since you made it to spec based on your forks, did you not make a two piece brace rather than a five piece?

[jwhelan65]

Great work Greg!

[rapidray]

but why, did you not make a two piece brace rather than a five piece?

How would you ever install a 2 piece?!!! A THREE piece maybe! If you saw it you wouldn't even ask!!! It's THAT nice & a PERFECT fit! Ray.