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Author Topic: Long awaited CB200 Build  (Read 9263 times)

Offline Erskine

  • Posts: 2163
Re: Long awaited CB200 Build
« Reply #30 on: Apr 10, 2016, 17:31:44 »

Offline bex

  • Posts: 80
Long awaited CB200 Build
« Reply #31 on: Jul 08, 2016, 03:01:39 »
Figuring out headlight and some mounts using bicycle seat post clamps. Saw someone (on here?) somewhere do this before and thought it was clever. There isn't much around at 31mm. Will come up with a nicer bracket now that I know it will work.

Working on a hydraulic brake conversion at the min, will post pics soon.






Offline bex

  • Posts: 80
Re: Long awaited CB200 Build
« Reply #32 on: Jul 09, 2016, 15:03:35 »
Started pulling together parts for hydraulic brake conversion. Waiting for a caliper to show up.

In the mean time got some bargain used parts off eBay, brake master cylinder and cable clutch. Smaller reservoir on the way as this one looks a bit big for the little CB.


Offline bex

  • Posts: 80
Long awaited CB200 Build
« Reply #33 on: Jul 16, 2016, 19:59:24 »
Been mocking up a bracket in card and then wood to take the Brembo caliper I've picked up for the front brake conversion.

It's not quite right yet in terms of shape and probably needs a bit more meat on the skinny bit up top, but here's the progress so far. It'd also be good to get some holes or slots in there to lighten it up visually, but I suppose I need to tread carefully or I will risk weakening it.

Some alignment issues to be sorted out with the wheel spokes and mounting points too.








Offline bex

  • Posts: 80
Long awaited CB200 Build
« Reply #34 on: Jul 18, 2016, 04:17:28 »
Round 2, and 3...

Going to get one laser cut in the correct thickness metal as it's difficult to fully appreciate alignment / any clashes otherwise and for now I'm happy with the fixing points, bottom mount obviously needing a good spacer. Also a friend suggested drilling out and retapping the mounts to take bigger bolts, which sounds like a good idea, providing there will be enough metal left around the holes.





And with a slightly fatter top curve, perhaps still too thin. May resort taking a straight line from top mount to upper Brembo mount in the end. Will see how the metal version turns out first.

« Last Edit: Jul 18, 2016, 04:20:16 by bex »

Offline xb33bsa

  • Posts: 7727
Re: Long awaited CB200 Build
« Reply #35 on: Jul 19, 2016, 22:58:01 »
looks good but the bottom bolt is only an m6 for a fender and having the spacer means it is depending upon the torqued up fastener to keep the assembly mimicking the diameter of the spacer as to shear loads
you want to make sure where the spacer plants is a true square surface and relieve the ends of the spacer so they plant down as if they were made of medium walled tubing however i think m6 is kinda small to get the desired effect m8 would be much better
i think it would be better to have the plate attach more outbored on the brembo like right under the bolt heads
this would shorten both spacers considerably

Offline xb33bsa

  • Posts: 7727
Re: Long awaited CB200 Build
« Reply #36 on: Jul 19, 2016, 23:08:26 »
and i dont like strengthwise the way you have scalloped out at the top below the bolt
we would rather see that as a full section ,it ie under twist/shearloads and being aluninum flexing must be kept to an minimum
you could atrfully do like 2 speed holes up there but not big ones like a 1/2 and a 5/8 no more no bigger
but you want to leave at least a holes worth of margin either side of any speed holes in this app so go by that

Offline bex

  • Posts: 80
Long awaited CB200 Build
« Reply #37 on: Jul 20, 2016, 02:36:21 »
Thanks for the comments - I did mention above about the scalloped area perhaps being risky, so I haven't quite decided what to do about that yet.  I'll probably straighten it off in the end as you say. Similarly about drilling out the both mounts to take bigger bolts if possible.

I looked at putting the plate on the outside of the brembo but this would mean machining off a substantial chunk off the fork casing at the upper mount, more than is available to me I think, as this mount is much longer - no spacer currently needed at the top. And without machining it would push the caliper much closer to the wheel which is a no-go, it's already a little too close and is clashing win some of the spokes, so I need to be pulling it the other way a few millimetres.

Lots of fiddly things to figure out with this one! :)

Offline bex

  • Posts: 80
Re: Long awaited CB200 Build
« Reply #38 on: Jul 24, 2016, 14:45:52 »
Getting the brake bracket cut in ally to have a real thickness mock up. In the meantime I was mocking up a headlight bracket today. Could have been the final piece but the ally I had kicking around is only 1mm, and it's a bit weak and bendy of course, so I will remake in 2mm soon.


Offline xb33bsa

  • Posts: 7727
Re: Long awaited CB200 Build
« Reply #39 on: Jul 28, 2016, 03:18:07 »
thats bitchen man
if you dont mind ne saying the hole is too big relagating any strength to the cross sections of material left
if i was doing it i would look at 2 other options for holes
3 holes 2 of them stacked vertically closest to the stanchion
then a 3rd larger hole closer to the light bucket
or just a large cutout leaving a very generous margin all arouind  but following the outside shape