Took some tinkering, but now I need a new GS500 rotor because I had to re-drill this rotor three different times before I got the pattern right.  I was disappointed that there wasn't enough room to mount an opposed piston caliper...my Tokico 6-piston pincers would have looked badass there.

Also whipped this up:



I made a manifold that bolts up to the carbs and hooks off the to right.  Despite the look it's completely clear of rider and pillion legroom.  Sounds f%$king badass too.  Filter off it sucks your pants leg into the bellmouth.  After I get the manifold blacked powdered it'll look pretty spiffy, too, I think.

New rotor, or "new" rotor?

So you have fitted a stronger caliper and at the same time weakened the disc where it mounts to the wheel-hub by drilling all those extra mounting holes..........yeah.... nice one.

drilling holes to mount the disc isn't going to weaken it, moron.

Yeah, moron. 


Zing!

Not going to weaken it, what gives you that idea??? get real man.  You drill holes in things you remove material, removing material from a load bearing area makes the component weaker and I would say the mounting area is a load bearing area, wouldnt you? Drilling extra holes in components that have been case or induction hardened will also weaken them.

If you put too many mounting holes in the disc over time it is likely to crack between the redundant extra holes due to heat expansion and stress, just like a dot to dot. Then it will start to flex and work harden, stress risers will build up and ultimately the disc will shear clean around the now weakened PCD just like a stamp rips off a sheet.

Mak? If you think its safe thats fine by me, carry on, after all its your arse on the line not mine but dont BS me by saying the disc wont be weakened, you are wrong. In some cases you can drill holes in material to stop cracks propagating. It works fine on non load- bearing thin sheet materials like plastics and fibreglass that are subject to vibration damage but these material are not subject to the shock and thermal loads a brake disc is.

Don't be such a twit.  5 holes isn't going to weaken the material no matter how hard you try to think about it.

If he gets an new disk and redrills them exactly between the old ones he should be okay, not the greatest idea or something I would personally but i give the probability of failing over time a 10:1 odds

This is assuming he does it too a new disk, the one he has on there now,ehhhh, probably not a good idea

^which is why I said I need a new rotor.  This one I got the pattern off by about a millimeter twice before getting it perfect.

Iain,
I think that pos is going to be used as a farm bike or something like that. 

Justin,
nothing really personnel, I'll admit my shaZam! is shaZam! and built from crap, but do you purposely go for the ghettoriffic look?

Quote from: werase643 on April 21, 2007, 08:21:36 PM
ustin,
nothing really personnel, I'll admit my shaZam! is shaZam! and built from crap, but do you purposely go for the ghettoriffic look?

The bike, as a whole, is crap...what can you expect for something that's basically free?  To date I have $7 invested in her, not including fuel.  If she turns into something worth pretty-ing up I'll pick up a chopper battery box, some K&N's, and put some quality paint on her.  When it comes to stuff like the brake setup...the only thing ghetto about it is the hanger made from mild steel.  Teflon line, 5/8" radial brembo master, rebuilt 2-piston caliper, hawk pads, the inner spacer is machined perfectly (something I'm quite proud of since I did it with a file, blade and drill press), and the rotor is within 1/1000 of an inch of perfect (holes bled into previous drillings...next one will be spot on).  Once I get some aluminum in I'll widdle me out another hanger and my titanium bolt set will be here monday so I'll have the proper profile fasteners to hold it all together neatly.

On the list of things coming in to stick on her:

Two 2X24" glasspacks and some stainless tubing to whip up an exhaust
A 2"X4"X2" aluminum block (new hanger)
15lbs of titanium fasteners
CB900C rear axle (only thing left I need to put a rear disc setup on the bike)
Sissy bar for the misses

Need to find....

Coils
New front rotor...thinking of picking up one of those wavey ones off ebay...and I may go for a 320mm rotor and offset it more with a spacer and see if I can wedge an opposed piston caliper on there (hello tokico 6-pot)
Better shocks...thinking CBR F3 Showas and 100lb springs

Justin, where ya gettin the Ti?
metric?
how much $?
just wondering.....
not like I have a JOB or anything right now.....

spent 5 hrs on the river today in a Kayak.....beautiful day to be unemployed!!!!!!

www.unitedtitanium.com and yeah metric assortment...about 15lbs worth and roughly $4/lb.

justin,
what you getting m5-m8 different lengths and m4-m8 nutz?

15 LB.....which salesperson did you use?

Quote from: werase643 on April 21, 2007, 08:56:14 PM
Justin, where ya gettin the Ti?
metric?
how much $?
just wondering.....
not like I have a JOB or anything right now.....

spent 5 hrs on the river today in a Kayak.....beautiful day to be unemployed!!!!!!

Hey Ken.As soon as I become unemployed Full time I'll try to come over and Bring some Beer. I'm not Much at Kayaking but tubing is More My Speed.

also have a canoe.....

and plenty of room

Okey Dokey.I Can't Promise Anything since I don't Fully Understand what all is going to happen yet.

not sure of the grades.  I hooked up with one of the sales reps through ebay last season...sent him an 11/16" Brembo radial master for $40 and he's making up the difference now with a bag of bolts.  I just told him a few typical ones I needed plus some odd-ball alan heads I needed...he's just throwing in a bunch of random others.

Mak.
Bolting a disc to a wheel is not like bolting a number plate to a mudguard. Have you considered the fact the disc is subject to a considerable radial load when the brake is applied? In effect the disc wants to shear away from the wheel hub when you pull on the brake. All the force and momentum thats in play when you brake passes through the disc and into the front wheel via the mounting bolts and the surrounding mass. By removing mass from this area you have reduced its ability to absorb and cope with the loads generated under braking and at the same time increased the chances of failure and fatigue.

Iain,
he understands
he don't care
this is a glorified dirt bike for the back yard