I had a leftover caliper from a 660 Rhino project that I worked on last year , it is brand new , I decided to see if I could make it work on here.
After looking at pretty much every CB200T hydraulic brake conversion I could find on the internet I realized two things, on every thread either they didn't have clear instructions and they didn't have clear pictures so I decided to just have a go at it myself , what's the worse than can happen ?
I made poster board patterns and remade them and remade them again till I thought I had something that would work , then I got it all cut out in metal and drilled the holes just to find out it still wouldn't work , so I then figured out a way to make it work.
This is defiantly not the path for everyone as it involves some aluminum work on the fork leg , but I do have a unique situation here , the bike came with an extra set of fork legs and the forks have to be rebuilt anyway , it also came with the new fork seals , at any rate here goes.
Basically the first bracket fits over the 8mm lug for the front brake , the second bracket goes on top of it and the 8mm bolt goes through both brackets , then the two fender bolts go through the second bracket as well .
I could probably just bolt the two brackets together but I feel more comfortable welding them together so there will be no flex, everything is made from 1/4" plate steel.
The bolt holding the caliper on still has to be ground down a bit and I messed up on the small bracket I will have to remake it and redrill the holes , hopefully I can get it dead on by using the first bracket and relocating the holes slightly , it would work as is but I am a bit of a perfectionist.
I hope the pics will explain this better than I can , all I have left is to put the fork leg on the bike and get the position right, clamp the two pieces together and weld it up. Of course I still need to make the other bracket and dress up the fork leg then maybe get the bracket powdercoated, I have a friend that does powdercoat on the cheap.