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Discussion Starter #21 (Edited)
Lathe Work

Here I'm turning down the OD on my external wheel spacers. The stock is 304L stainless which is supposed to be free machining. Since this whole front end is a one off project I have to fabricate custom wheel spacers. After some careful measurements with gauge blocks and then calculations I determined that the spacers needed to be .931 in. in length. Here I'm turning down the OD to 1.275 in.
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Here I'm facing off the end of a bushing to .931 in. overall length. The bushings had to be bored out for a 25mm axle.
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The front wheel should be within + or - about .020" of the centerline between the two forks. I think I was able to do this although sometimes it's hard to determine this as sometime the forks have no place to measure off of because they have no machined hard point on one fork slider especially if the bike came from the factory set up only for one brake rotor.
 

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Discussion Starter #23
Here are the completed outer wheel spacers. I believe they're pretty close to the same length. I miked the depth of both wheel bearings and I think they were only about .005" difference on their depths. I stamped them "R" & "L" just in case so they don't get mixed up. I've noticed on my Dyna that the stock front outer wheel bearing spacers aren't the same width
Outer Wheel Spacers.jpg
s! Go figure!
 

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Discussion Starter #24
Tuesday I took my rim to Junction City Cycles in Junction City KY Junction City Cycles to get the Dunlop Sportmax Roadsmart 3 120/70ZR18 tire installed. Here I've just installed the Brake Tech 320mm free floating rotors after removing the stock XR1200
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292mm rotors.
 

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Discussion Starter #26
I've put together my front end here. Everything looks good and my wheel seems to be within about .005" of the centerline.
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Discussion Starter #27
Here's a shot of Mad Max's [my 87 FXR] front end. The setup on Red is going to be very similar except for the XR1200 wheel. Max has a Dyna Fat Bob front end which sports a 130/90B16 tire and 300mm diameter rotors.
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Discussion Starter #28
Here I've done a mock up with my V-Rod fender. Unfortunately it's going to running a wee bit high. The original V-rods ran a 120/70ZR19 front tire [XR1200 runs a 120/70ZR18]
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so there's going to be a gap but I can live with it. I may get my body man to bob the fender supports eventually.
 

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Discussion Starter #30
Here I've done a mock up with the 6 piston 'Busa Tokico caliper. It fits and clears the spokes. The next step will be to fabricate some one off T6 .500" aluminum plate adapter brackets.
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Discussion Starter #31
I've sent two messages to the moderator to try to get this post moved to the Tires, brakes, wheels and suspension section but I've never got a reply! Anyhow I've not been doing too much on it lately but I did get my front fender assembled: Here I've got my V-Rod fender assembled. It was just a matter of collecting the right fasteners and bolting it together. Harley in it's infinite wisdom decided that the V-Rod had to have a two piece front fender [go figure!] I'm running V-Rod sliders on this front end project. Of course it still has to be painted red and some art deco work put on it.
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Discussion Starter #32
I've just finished rebuilding my 'Busa caliper after soaking them in kerosene for several days. This is to disolve all of the Dot 4 brake fluid residue in the calipers. I'm running Dot 5 in the new setup and Dots 4 and 5 don't mix well. I've done this before and it works well. Here's pix of my new brake pads which are EBC HH compound which turned out to be what the factory used [the HH compound]. I was surprised that these were made in Amerika. I thought EBC products were made in Europe! After cleaning out the O-ring grooves with a wire brush I installed a new Suzuki rebuild kit in both calipers.
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Discussion Starter #33
Here's a pic of my left hand caliper fully rebuild and reassembled. I haven't reinstalled the antirattle shields yet because I still have to locate the bolt holes for my one off adapter brackets and I have to be able to see the pads so they line up with the OD of the 320mm rotor.
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