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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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Discussion Starter #34
Here I'm drilling mounting holes in the caliper bracket so I can bolt the caliper onto my V-Rod sliders. It's .500" T6 6061 aluminum plate. However after trying to fit it onto the slider I realized that there was a fitment problem and the .500" plate bracket wasn't going to work. On my previous two front end upgrades on my Sportster and FXR I used a piece of 1.000"x2.000" T6 6061 bar. You can use the .500" plate for Harley calipers but it won't work on a 'Busa Tokico caliper because of the slightly different geometry on them. The bracket has to be made with 1.00" bar stock and you have to machine an offset onto it for proper fitment. I can't use the older brackets on my Sporty or FXR because I'm running the new 320mm Brake Tech rotors not the 300mm Harley rotors. So I had to order some more 1.000"x2.5000" aluminum stock from Online Metals for the brackets. Here's a link to the XL Forum which has my post on the Sportster fork upgrade which is similar to the current Dyna upgrade. Sportster Fork Upgrade - The Sportster and Buell Motorcycle Forum - The XLFORUM®
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Discussion Starter #35 (Edited)
I got in my bar of 1x2.5x12" T6 6061 aluminum but unfortunately it's not tall enough for this job so I've got to go to plan "B". In the pic is the Al bar and to the left is my template which I used for fabricating my previous brake upgrade projects where I ran the 300mm H-D rotors with the dual 6 pot Tokico calipers. With plan B I'll be using the .500" plate along with a couple of .750" diameter offsets.
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Discussion Starter #37
Now I've got to transfer the caliper mounting bolt holes from the calipers over to the adapter plate. This isn't as easy as I'd thought and I had to fab this on off transfer screw from an M10x1.25mmx50mm screw by turning it down on my lathe to a 60 degree included angle. This wasn't a very good set up and I had some runout in my screw however not enough to mess things up.
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Discussion Starter #38 (Edited)
Here I've got all my caliper mounting bolt holes all drilled out and done a full scale mock up. This will give you a better idea what the final set up will look like. I still need to get some M10x1.25x60mm screws to mount my calipers. You can see the aluminum .750x1.00" offsets supporting the caliper. I laid out the caliper bolt holes so the tops of the pads are even with the outer diameter of the 320mm rotors to give maximum stopping power.
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Discussion Starter #39
Here the left side bracket is installed and a full scale mock up with caliper. It's a mirror image of the right side bracket. Both still have to have finished finish machining and the corner radii installed.
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Discussion Starter #40 (Edited)
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Hmm, my post seems to have vanished! Anyhow I finally got the right side done! Here's a pic of the final assembly. I got the adapter brackets machined down and the .375" corner radii installed [had to do that by hand]. I've still got to cut down the two .750" aluminum standoffs on the left side down a bit. The rotor is not quite centered on the two caliper halves.
 
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