Friday update: Body work, brakes, controls
Started off the day by making the brake caliper carriers and welding them on. Started with this:
And ended up with these:
When I made the mounting hubs for the disks I was shooting for as short as possible without the calipers rubbing on the tires... nailed it!
Bolted them up, did a quick alignment, and tested range of motion. Marked up the body work and trimmed it so the wheels now clear:
With that done, I started in on cable routing and controls. Here is the basic concept I came up with:
Then took apart the steering column and stripped out all the excess wiring and electronics. I trimmed the the console plastic to move the throttle inward on the handle bars and cut a hole behind the headlight to run the brake and clutch cables into, but given the angle it puts the cable at I'm going to end up doing something different.
I measured out the throw of the ATV throttle vs. the carburetor, and it is only about 75% of what I need to get full juice.
I used a die grinder to remove some internal stops to get more, but it's still going to need a secondary mechanism to achieve the correct motion ratio. Here is the max I get currently:
Moving on to hooking up the brakes, I used some roll pins and #6 nuts to make cable stays:
Welded them onto the frame, hooked it all up, and here it is:
I tuned them in so they are balanced, then took it for a test ride down the hill I live on. They do the job, but the motion ratio on the lever is designed for one caliper not two so effort it high. Going to have to change that.
More bits showed up in the mail today, so more to come tomorrow
