I finally had the chance to start fitting up the wheels and brakes.



I need to make a small shim (o.5-1.0mm) to give a bit more clearance between the caliper and the disk on the trailing edge;

The leading edge is ok.

And I need to order 5mm longer bolts for the bracket. The should be M8 x 35. Not sure how I stuffed that up.


The next was a mod I knew I needed to do. The lug for the speedo drive needs to be cut down to clear the wheel.


About 5-6mm needs to be cut off.


Even so the wheel is quite close, I need to make up a washer that is 3mm thick or make longer spacers.


So I could change back to the standard wheels and speedo drive I drilled and tapped the lug for an M4 capscrew to go in.

As you can see from the following photos it gets pretty close in the front end.



The fork guards may need to be trimmed a small amount.




The rear end went together very neatly.



Now I just need to order a master link to make a shorter chain and order the M8 capscrews before I can give it a ride.

looking very nice!

maybe when I get back to the UK I will try an do a CRM properly...

All I can say is WOW I'm impressed

Thanks for the kind words.

I have put an order in for the chain master-link and longer bolts. More progress in a few weeks time when those parts get here.

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.





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.

getting there

Looking forward to seeing photos of the bike when finished.

Dirty!


The cleaned up caliper







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.



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.


If I drill the boss for a new banjo fitting the hose should run nicely through the standard CRM hose clamp.




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.

It's certainly coming on

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

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.

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.


Plenty of clearance now.


Marking & machining the cross-feed gallery;




Counter boring for the seal


Drilling the gallery that connects to the pistons


Machining the boss for the M10x1 banjo fitting






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.

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

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