MK2 with Aprilia Parts (In Progress)

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Re: MK2 with Aprilia Parts (In Progress)

Post by Speeddevice » 21 Dec 2015, 09:24

The bolts have come in and are now installed.
The chain link is here too. I just need to shorten the new chain and install it now.

I made a spacer for the front wheel but some how grabbed the dimensions as 22x35x3 instead of 22x28x3. The larger OD hits on the casting where the bottom of the fork tube goes in. I could wait till tomorrow and make a new one but decided to make a flat on one side for clearance instead.

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I should be able to connect the front brake hose and bleed the system but I was thinking of giving the master cylinder & original caliper a bead blast first to clean them up.

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Re: MK2 with Aprilia Parts (In Progress)

Post by jompy » 21 Dec 2015, 14:26

getting there :)

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Re: MK2 with Aprilia Parts (In Progress)

Post by andrew19 » 21 Dec 2015, 19:47

8-) Looking forward to seeing photos of the bike when finished.

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Re: MK2 with Aprilia Parts (In Progress)

Post by Speeddevice » 03 Jan 2016, 03:56

Dirty!
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The cleaned up caliper
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When I started to tighten the real axle I found a problem. The sprocket carrier is hitting on the swingarm weld. I should have left a couple more links in the chain and it would have been ok. I'll have to take it out and turn 3-5mm of the carrier, which will give it much better clearance anyway.
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The hose doesn't quite reach the original RS banjo hole on the caliper unless it runs wide of the fork, where it could get caught.
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If I drill the boss for a new banjo fitting the hose should run nicely through the standard CRM hose clamp.
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And the sidestand needs to be about 25-30mm shorter. I think I will make/buy a second one so the original can be swapped back in with the wheels.

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Re: MK2 with Aprilia Parts (In Progress)

Post by jompy » 03 Jan 2016, 11:35

It's certainly coming on :)

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Re: MK2 with Aprilia Parts (In Progress)

Post by Sean91 » 03 Jan 2016, 22:10

how come youve changed the front calliper to aprillia and then youve put the original front brake on the rear? wouldnt it make more sense to put a rear brake on the rear? i also dont understand the reasoning for a shorter side stand, the original one is short enough already, even with smaller supermoto wheels fitted :|
your original master cylinder looks a lot better condition than mine though

sean

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Re: MK2 with Aprilia Parts (In Progress)

Post by Speeddevice » 06 Jan 2016, 07:40

Hi Sean,
sorry for the confusion.
I cleaned the CRM front caliper so I can put it on the bike when swapping back to the CRM 21" & 18" wheels.

Just to clarify, when fitted with the 17" Aprilia wheels the CRM will use the Aprilia front brake caliper on the front and on the back will be the CRM rear caliper on the Aprilia disc.

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Re: MK2 with Aprilia Parts (In Progress)

Post by Speeddevice » 06 Jan 2016, 08:16

Mounting the sprocket carrier to the faceplate on the lathe was a little difficult.
There was around 0.5mm of runout but it won't affect balance and isn't required to be parallel.
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Plenty of clearance now.
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Marking & machining the cross-feed gallery;
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Counter boring for the seal
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Drilling the gallery that connects to the pistons
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Machining the boss for the M10x1 banjo fitting
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Little bit annoyed that the paint was damaged on one side of the caliper by the solvents in the cutting fluid.
Will need to repaint it.

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Re: MK2 with Aprilia Parts (In Progress)

Post by Sean91 » 06 Jan 2016, 08:27

I see, do you prefer the offroad wheels or are you going to keep both sets of wheels for different sorts of riding? By the way I really appreciate the amount of precision used on the brake, great stuff!! :)

Sean

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Re: MK2 with Aprilia Parts (In Progress)

Post by jompy » 06 Jan 2016, 20:47

i wish i had access to and could use all that equipment , i have a few things i need knocking up , best get my finger out & pop round to see the eccentric engineer

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Re: MK2 with Aprilia Parts (In Progress)

Post by Speeddevice » 27 Jan 2016, 12:01

Hi Sean91,
I haven't tried the bike as a motard yet, so that was my main motivation to try this and do it without spending a fortune. I was always keen to be able to use it on dirt or tarmac.

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Hi Jompy,
Glad you like the work. Never underestimate what you can do, even with hand tools. The most important thing is to have a go.

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I made a new sidestand that was a little bit shorter.

I ordered a banjo bolt to blank off the lower port on the caliper. Excellent looking piece, M10 x 1.0 but then I was confused because it wouldn't screw in. Had I tapped the wrong thread size? The original fitting screwed into both ports, did I measure it wrong?
Nope, I used a M6x1.0 (standard metric size) to check the thread pitch and it was wrong. Somehow there was a 3/8" banjo bolt inside the M10 x 1.0 packet.
Just waiting for the correct part to arrive now.

Trying to get photos up but having trouble at the moment.

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Re: MK2 with Aprilia Parts (In Progress)

Post by Speeddevice » 28 Jan 2016, 10:28

Started with a rusty lump of steel and some tubing for the side stand
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Used the mill, hand file, angle-grinder with flapper disc and linisher to shape the mounting boss
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All the bits ready for welding
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The foot tack welded on for testing before being fully welded
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A bit of black paint to make it look good
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The front brake and brake hose fit nicely
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Re: MK2 with Aprilia Parts (In Progress)

Post by andrew19 » 28 Jan 2016, 17:46

Nice work :BB

Your lucky to have lathe and milling machine to make such parts (and know how to use them!!)

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Re: MK2 with Aprilia Parts (In Progress)

Post by Speeddevice » 04 Feb 2016, 02:55

Thanks Andrew,

It's one of the perks of work.

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Finally got the right banjo bolt and blanked off the lower port.
Took a while to bleed the brakes from bone dry. After an hour or more I finally had the pads biting with a soft lever feel, so I tried the Motorcross trick of strapping the lever in with some Velcro (a cable-tie is normally used) then left it overnight. It feels fairly solid now but there is a bit of give with the stock CRM brake hose expanding. It would be worth investing in a new hose or braided line.

So far I've only given it a quick ride up & down the driveway (~30m).

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Re: MK2 with Aprilia Parts (In Progress)

Post by Sean91 » 04 Feb 2016, 08:34

Ive noticed quite an improvement in braking on my bike since i replaced the stock hoses for new braided ones. Id say they would be well worth the investment :)


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