Comstars + gsx-r front end

THat's similar to what I'm trying to do for mine:
adapter.jpg


I suppose i could just get the spacer machined without the holes, then use the rotor as a template as you did.

Then in order to properly clock the new rotor, I'd want to make the adapter first - Then clamp the pieces together somehow in order to keep everything from rotating throughout the drilling process?
 
If you are sending the spacer out to be machined by someone else, then get them to do the holes. Any shop with a CNC just needs to know the diameter of the pattern and the amount of holes. Then use the spacer to measure up your rotor.
 
Makes sense... what's the best way to measure the diameter of the pattern - do you measure from the ID of the entire piece to the edge of the hole, or center to center?
 
rs_ss350 said:
Makes sense... what's the best way to measure the diameter of the pattern - do you measure from the ID of the entire piece to the edge of the hole, or center to center?
What rotors are you using? The pitch circle diameter(PCD) for the comstar bolts is as follows: ⌀78mm (5)⌀8.5mm. The center hole or rotor carrier flange is ⌀58mm
 

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What OD on these? Metalgear shows a rotor with 78mm dia 5 bolt pattern with 296mm rotors. You might be able to make those work, if you can figure out what bike they're off of. There might be something else for a different dim.

http://www.metalgear.com.au/mgear-brake-disc-front-p-6786.html
 
irk miller said:
What OD on these? Metalgear shows a rotor with 78mm dia 5 bolt pattern with 296mm rotors. You might be able to make those work, if you can figure out what bike they're off of. There might be something else for a different dim.

http://www.metalgear.com.au/mgear-brake-disc-front-p-6786.html
that's the same rotor on my cx, and I'm pretty sure all the comstar wheels. Which is 296mm. GSXR 6-1K is 310mm and the Busa <07 is 320mm. I'm not sure what gsxr front end he is using. But at minimum, if it is radial mount calipers they accept 310 or 320(with 5mm caliper spacers) rotors
 
These are the rotors I'm trying to use. https://www.ebay.com/itm/162371524479 looks like the OD IS 300... assuming that's not gonna work? I'll probably then have to use the gsxr set I have.

These are the forks https://www.ebay.com/itm/172568993897
 
Those rotors are 300mm. I usually try to match rotors to the front end, unless the bolt pattern is a match, then I focus on OD. You're going to need to figure out a way to run your calipers with 300mm rotors instead of 320mm to run that setup. The GSXR is 6 bolt. You're going to have to draw up the pattern to see how the holes line up. It's usually pretty messy.
 
Hmm, something is off on the gsxr rotors I bought then... these have 5 holes... https://www.ebay.com/itm?itemId=322469292439
 
Any other rotor suggestions are welcome :). What's another pair of rotors for the sake of getting it right?
 
rs_ss350 said:
Hmm, something is off on the gsxr rotors I bought then... these have 5 holes... https://www.ebay.com/itm?itemId=322469292439
That they are. My bad.
 
Here's what I would do:
It appears the rotor center spacing is 132mm. The hub is 70mm on Comstar, from rotor mounting surface to rotor mounting surface. Your rotor spacer has to be 28.5mm on each side to correctly space the rotors in the center of the calipers. Next get some Hayabusa rotors, specs on those are PCD: 91mm; (5)10mm mounting holes; OD: 320mm; ID: 69mm; Thickness: 5mm
Clock the rotor spacing to the Comstar hub spacing on your 28.5mm spacer ;D EDIT: you'll want to countersink the mounting holes from spacer to hub
Then you will need 5mm caliper spacers, cheap to buy or I have a drawing to get them made. I had mine made.
 

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erock85 said:
Here's what I would do:
It appears the rotor center spacing is 132mm. The hub is 70mm on Comstar, from rotor mounting surface to rotor mounting surface. Your rotor spacer has to be 28.5mm on each side to correctly space the rotors in the center of the calipers. Next get some Hayabusa rotors, specs on those are PCD: 91mm; (5)10mm mounting holes; OD: 320mm; ID: 69mm; Thickness: 5mm
Clock the rotor spacing to the Comstar hub spacing on your 28.5mm spacer ;D EDIT: you'll want to countersink the mounting holes from spacer to hub
Then you will need 5mm caliper spacers, cheap to buy or I have a drawing to get them made. I had mine made.

Thanks! that's all super helpful. Questions...

Are these the rotors you're referring to? http://www.ebay.com/itm/99-07-SUZUKI-HAYABUSA-GSX1300R-ROTORS-FRONT-BRAKE-DISC-WHEEL-OEM-STRAIGHT-/252966078859?hash=item3ae5f4098b

for the spacer, I understand countersinking the holes for mounting to the hub (what diameter would that be?). If the hub mounting surface is flat against the hub, how do the rotors get mounted?
 
rs_ss350 said:
Thanks! that's all super helpful. Questions...

Are these the rotors you're referring to? http://www.ebay.com/itm/99-07-SUZUKI-HAYABUSA-GSX1300R-ROTORS-FRONT-BRAKE-DISC-WHEEL-OEM-STRAIGHT-/252966078859?hash=item3ae5f4098b

for the spacer, I understand countersinking the holes for mounting to the hub (what diameter would that be?). If the hub mounting surface is flat against the hub, how do the rotors get mounted?
Yes, those are the year rotors you want 99-07
The diameter would depend on the mounting hardware you are using. If you go with allen head bolts, which i recommend, you would need to make them the diameter of the head of the bolt. You can find those specs online - McMaster Carr
The rotor mounting holes would then have to be a threaded hole and you can use the stock bolts that Suzuki would have used. part #http://www.partzilla.com/parts/detail/suzuki/SP-09106-08148.html
I think they are M8x1.00 Edit: They are M8x1.25
 
Fantastic - thank you! Would Aluminum 6061 be the proper material to use, for the adapters and the axle spacers?

Just thought of something... even if using allen head bolts, I'd still need hex nuts for the other side? and then enough clearance to get a socket in there?
 
rs_ss350 said:
Fantastic - thank you! Would Aluminum 6061 be the proper material to use, for the adapters and the axle spacers?

Just thought of something... even if using allen head bolts, I'd still need hex nuts for the other side? and then enough clearance to get a socket in there?
To mount the spacer you will be using the old rotor mounting points on the comstars, which is a threaded hole through the hub. An allen bolt would suffice to mount the spacer to the hub. Then use the rotor mounting hardware to mount the rotor to the spacer using the threaded holes created in the spacer. No nut is needed
6061 is perfect for this application, strong enough and easy enough to machine.
 
Hmm, when I took the existing rotor off my Comstar it was fastened by a long bolt that went straight through the hub with nuts on the end. I'll investigate more this afternoon. could be the PO did something funky there.... Also this wheel was originally fitted with only a single rotor. I wonder if that makes a difference with the hub? Seems like two rotors would mount fine.
 
rs_ss350 said:
Hmm, when I took the existing rotor off my Comstar it was fastened by a long bolt that went straight through the hub with nuts on the end. I'll investigate more this afternoon. could be the PO did something funky there.... Also this wheel was originally fitted with only a single rotor. I wonder if that makes a difference with the hub? Seems like two rotors would mount fine.
Interesting..mine too was a single rotor with a cap on the other side without a rotor. I used the old rotor mounting point and the cap mounting holes for my application
 
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