CB550 Custom Rear-sets

[FunJimmy]

Making rear-set controls for my recent CB550 Interceptor project was one of the most difficult tasks to date. These old pull rod drum brake bikes pose the unique problem of transferring the brake pedal leverage to the drum brake arm. I’ve seen several approaches from using a brake cable to the more common attempt of integrating the stock pivot shaft and pull rod with various linkages.

Neither approach seemed like the right one to me. I wanted to remove all the stock brake actuation hardware so I could locate the rear-sets wherever I wanted, without the restrictions the factory brake pivot imposed. A flexible brake cable would certainly offer the flexibility I was looking for but they are difficult to integrate into the design and require a custom cable and adjusters at both the rear-sets and the brake drum.

Once I cut the passenger foot peg mounts and ALL the brake hardware off my frame, I could start figuring out the layout for the rear-sets.

A method of mounting was the first task and for that I made 9-way adjustable aluminum plates that mount to the frame using the swing arm pivot bolt and the lower engine mounting bolt. Aluminum is excellent for making rear-sets from because it is so easy to work with. All the flat aluminum parts are cut and shaped using a band saw, drill press, and draw files.

 

[FunJimmy]

It took many more cocktail napkins to work out all the linkage logistics than first thought. The most challenging aspect of the design was transferring the brake pedal motion to the rear brake drum without a loss of efficiency and feel as there is so much offset between the two levers. Every way I looked at this problem flex and distortion was the biggest concern, but I finally designed a system that worked.

 

[FunJimmy]

I just have to spend a little time turning down the foot pegs and knurling them for traction before the anodizer colors them black.

 

[FunJimmy]

Now the rearsets have a 9 position range of adjustment without affecting the shifter or the brake action.

 

[FunJimmy]

The splined shifter arm and rod are from a 2006 CBR1000R and fit perfectly.

 

[FunJimmy]

When I set out on the mission to build rear sets for my Café Project bike I didn’t think that it would be as much work or as rewarding as it’s been. At the onset, the goal was just to build a nice set of controls fabricated from any number of parts sourced from wreckers or ebay and modified using the occasional part made from scrap aluminum. Only when I started making parts did the focus change to a complete custom set designed and built to the best of my abilities and to function as well as they can. It’s been the biggest single task of the project and I’m very proud of the outcome.

Here they are straight from the anodized and ready to be installed.

 

[autoguy]

thems some fine looking rear sets

 

[Texaninseattle]

how much for a set?

 

[FunJimmy]

how much for a set?

You tell me! ;D

 

[Hot Rod Troy]

Awsome work, Jimmy. They turned out beautiful.

 

[DrJ]

Holy crap, that's gotta be the best custom rearsets I've ever seen

 

[locOleoN]

yeah.. very well done...
how long did it take you to make?

There are a lot cb550ers on this board that would love that set up!!

You should consider putting up an offering to the cb550 guys

 

[saucer]

would you consider making just the foot pegs , and levers? i'm considering getting some tarozzi, but i like yours better,

 

[FunJimmy]

I'd love to be able to offer the community these rear-sets, but in all honesty these took forever to make.
I might look into getting a machine shop to reproduce them if the interest is there, but with approx 24 individual parts required the quantities might need to be high.

Post your votes here and I'll look into it.

Thanks guys.
Jimmy

 

[kodiak]

I'd love to be able to offer the community these rear-sets, but in all honesty these took forever to make.
I might look into getting a machine shop to reproduce them if the interest is there, but with approx 24 individual parts required the quantities might need to be high.

Post your votes here and I'll look into it.

Thanks guys.
Jimmy

Most shops will charge a minimum of $100 per individual set up... You talking some serious dough if its not done in mass quantity... best bet to have them estimate is having all the parts nested in one plate... that way you'll pay one set up charge and one initial charge for making a fixture plate to hold it... I'd love to help you guys out, but unfortunately they just laid the smackdown on government work here... I can't even get my new set done that I was planning... At least I got my first version done so I'm operational though....
BTW, damn nice work...

 

[Deviant1]

VERY nice work! Those are amazing man. They look like you paid a princely sum for them! The anodizing looks very nice as well.

 

[cafe kid]

Awesome work! Depending on price you 've got my vote!

 

[listo]

Very nice. Do they work with the kick starter? I'd be interested in a set if they do.

Thanks

 

[FunJimmy]

Do they work with the kick starter?

Currently NO! If I made the peg pivot up it would work fine.

 

[Timiskin]

I would be in for a set.