Rear Disc Guard

Post by **Jonorow** » 10 Nov 2006, 18:14

Just thought I'd share a little mod with you that i have just done. I decided to protect my rear disc a bit after me experiences at my local track. I bought one of these fastway aluminium chain guards but the disc carrier isn't drill so with some carefull machining. This is the result.

mickstoy · Post by **mickstoy** » 10 Nov 2006, 18:22

looks good m8
when you say a bit of carefull machining what did you have to do? and where did you get the guard from?
mick

Post by **Jonorow** » 10 Nov 2006, 19:56

I got the guard of ebay from team filipe ( you should find them easy) i have a pillar drill and drilled with a 6mm drill from the back to start the hole (the one is on an angle which is where the carefull machining comes from!!) drill through with a 5mm drill and tap a 6mm thread. The guard needs to be recessed slightly to let the bolts (supplied) fit between the hanger and the swingarm. you might also want to file the welds back slightly to give a bit more clearance, as there is less than 1mm when fitted. Hope this helps and good luck if you fancy fitting one.
Jon

CRMR · Post by **CRMR** » 11 Nov 2006, 09:07

That looks soo cool , Im gonna do it ..Bought of team filip before , Hes a good ebayer....

Well done

TOXIC · Post by **TOXIC** » 11 Nov 2006, 15:52

Jonorow

That look dam nice

as well as being very usefull think i will copy you on that if you dont mind mate

Toxic

CRMR · Post by **CRMR** » 11 Nov 2006, 23:22

whoooo hold on ,,, hold on just a minuet..checked ebay , found one for £33 plus extra for p+p.....Nooo whay... im gonna show you how to make one just like it in the next week or so ,,
the projects on ,
Im gonna make one just as good for less than a tenner...

watch this space

TOXIC · Post by **TOXIC** » 12 Nov 2006, 20:33

ok if you can save me a few ££££ them im happy to wait a week or so

after all the new CDI unit cost me a bit

Post by **Jonorow** » 12 Nov 2006, 21:12

If you want lads, I can trace the shape with measurements to save you some trouble. oh and if you can cut it out of 8mm ish aluminium with a hack saw, you have more patience than me. Jon.
I need to clean the bike this week after a day on the motocross track. this bike flies with a 48 ring on the back, just dont try keeping up with the crossers with enduro tyres, you wont do it!!!

CRMR · Post by **CRMR** » 13 Nov 2006, 16:29

That would help jonorow..Basically the important bit would be to get the screw fixing distances right ..

Whats the distance along the top
where are the holes positioned in relation
how wide is the lip (bit that protects the disc)
is the lip flat 90 deg or slanted to redirect objects/mud

Thanks in advance

CRMR · Post by **CRMR** » 18 Nov 2006, 10:08

gonna make one today ,,work out my own measurements and post a photo log

Post by **Gwyn** » 18 Nov 2006, 11:13

Good man crmr. keep us informed how you get on.

CRMR · Post by **CRMR** » 18 Nov 2006, 20:36

Its done , Cost me £3.99..Will post all the photos and instructions later..
If i had one wish it would be to have used 4mill alloy instead of 2 mill.
looks cool though

hursty · Post by **hursty** » 19 Nov 2006, 09:35

how hard was it to fabricate dude, as i would like to attempt one myself!

Post by **Jonorow** » 20 Nov 2006, 21:36

Ok men the disc gaurd i fitted was only 19.99, plus about 2.50 postage, and was bought from http://stores.ebay.co.uk/TEAM-FILIPE. Not an expensive road and after 2 trips around the motocross track it has stood up well.
After CRMR has done such a marvelous job on his disc guard I will also do a step buy step on How mine was fitted. I did use a pillar drill and a hole tap, but if these aren't available to you then a mix of the two fittings may be in order. Watch this space........ or one slightly bellow it!! Jon

Post by **Jonorow** » 23 Nov 2006, 18:01

Well, here we go, as promised!

Remove the rear wheel and disc carrier. remove the retaining cap and bolt then remove pads and caliper to leave thecarrier on its own.

Using a 6mm drill bit in a drill press, start drilling one of the tabs from the rear (Inside as it is mounted) untill you have a 0.5mm hole. This is to position the hole correctly in the tab.

Then using a 5mm drill, drill through the tab. This can then be tapped with a 6mm tab. (dont worry about these sizes they are correct. 5mm drill for 6mm tap)
http://193.116.26.75/uploaded/CRM_jono_012sm.jpg

complete the otherside taking care when drilling the slopeing side!
http://193.116.26.75/uploaded/CRM_jono_010sm.jpg
http://193.116.26.75/uploaded/CRM_jono_007sm.jpg

next you will need a 12mm drill bit or a counterbore (countersink) bit.
Take the rear guard and counterbore the far right hole and the second from the left (see pic) only go so far so the supplied bolts are recessed slightly.
http://193.116.26.75/uploaded/CRM_jono_014sm.jpg

You can new screw the guard onto the carrier with the supplied bolts. You will need to check that the bolts do not protrude to far the otherside and interfear with the disc.

Check the fitting on the bike. You may need to file the weld slightly to give enough clearance, but may be ok.
http://193.116.26.75/uploaded/CRM_jono_004sm.jpg

Reasemble the caliper to the carrier and refit on the swingarm. Refit rear wheel and adjust chain.
Your newly fitted Guard should look something like thepicture at the top of this post.
Good luck. Jon