Disc brake setup for oldie
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Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7094
Location: Victoria, Australia
Sun Sep 01, 2013 4:12 am quote
The point of my other thread here - Fork Swap for 150 Super - was to get ready for a disc brake front end on my '75 VBC. I finally got it done this weekend after some months of tortuous procrastination.

My main aim with this was to build something that could be assumed by the general public to be a stock fitting... well at least not to look too much out of place. And keep costs down while doing so, which is why I chose the Scoot R S kit. A friend had put one on his and it worked beautifully, so that's the direction I went.
The thing I didn't like about them was the master cylinder attachment which went against the original aim of looking stock-ish, so I collected pictures and info wherever I saw a good idea. Initially I was going to have my headset welded with an aluminum mounting plate and I got a quote of $80-100 to do it, but when it came time I didn't have the money spare. So I ended up going via the GSF (http://www.germanscooterforum.de/topic/14540-bremspumpenhalter-für-grimeca-griff) route and I'm very happy with the result.

I started by buying a Grimeca master cylinder and working out how much material needed to be removed from the headset. I cut off what I thought was probably the right amount, leaving the lever bolt hole. Unfortunately the bottom section had a crack that I hadn't seen, so when that was cut it came away. But I think that actually worked to my benefit, enabling me to use the long nut arrangement you see here.



I got a bit of scrap 3mm steel and cut it roughly to shape.



Shaped up a little and bent.







Painted and fitted the hose. It's very stiff and hard to get into tight spots... next time I'll use the thinner SIP hose kit, which has ends that come off, allowing you to thread it through smaller holes.



I used an M8 button head cap screw for the outer fixing and painted the head... you hardly see it now. At first I was a little worried about the small bit of the casting supporting the load, but the whole thing is quite strong and is not carrying much load if any in the up-and-down direction where it's weakest.



All together. Fairly neat I think.



The complete setup.



Getting everything in the headset working properly and fitting wher it would't all bind together was the biggest PITA but it works really well now.

Last edited by Ginch on Mon Nov 04, 2019 12:00 am; edited 1 time in total
Molto Verboso
1963 VBB2T
Joined: 07 Nov 2012
Posts: 1103

Sun Sep 01, 2013 9:41 am quote
I'm really impressed Ginch, great job. Gotta chuckle at the boots.
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7094
Location: Victoria, Australia
Sun Sep 01, 2013 1:59 pm quote
Lynnb wrote:
I'm really impressed Ginch, great job. Gotta chuckle at the boots.
Thanks! I saw that in the pic and thought, nobody will even notice! Forgot where I was I guess!
Ossessionato
PX200, Moto Guzzi V7 Cafe Classic
Joined: 22 Nov 2011
Posts: 2115
Location: Sydney, Australia
Sun Sep 01, 2013 3:48 pm quote
Very nice work. Just in time for the Mille.
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7094
Location: Victoria, Australia
Sun Sep 01, 2013 7:04 pm quote
Bobo wrote:
Very nice work. Just in time for the Mille.
He he! Just!
Mr. Clean
P,SUPER,V90, 50 Special
Joined: 27 Jul 2010
Posts: 10207
Location: This is't my locker!
Sun Sep 01, 2013 7:49 pm quote
Great job G! looks really pro!
Member
gts 250, px200, t5
Joined: 07 Jun 2010
Posts: 17
Location: South Oxfordshire
Mon Sep 02, 2013 11:29 pm quote
Hey, that's nice ! I had a GS frame a few years ago and I spent a long time trying to figure out how I was going to get a hydraulic conversion on it ... and I thought .. and I thought ... and then I sold the frame.

Your conversion looks factory fitted; nice work !
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7094
Location: Victoria, Australia
Tue Sep 03, 2013 2:06 am quote
portly wrote:
Hey, that's nice ! I had a GS frame a few years ago and I spent a long time trying to figure out how I was going to get a hydraulic conversion on it ... and I thought .. and I thought ... and then I sold the frame.

Your conversion looks factory fitted; nice work !
Thanks! Some time later I'll change the hose for a less obtrusive look.
Molto Verboso
No moar Vespas...sold them all
Joined: 09 May 2012
Posts: 1087
Location: Denver City Denver
Tue Sep 03, 2013 10:36 am quote
Wow...looks really clean. I like it!
Banned
GTS 300
Joined: 25 Jul 2013
Posts: 417
Location: Rancho Mirage Calif
Tue Sep 10, 2013 5:56 pm quote
.....
Great job, should make a cnc bracket kit for others
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7094
Location: Victoria, Australia
Tue Sep 10, 2013 6:16 pm quote
Re: .....
GEE-BEE wrote:
Great job, should make a cnc bracket kit for others
You can buy one from Scooter-Center... a bit pricey for what you get (€30 + postage from memory) and quite simple to make. Even mine at 3mm thick is probably thicker than it needs to be.

7670426 (1).jpg

Veni, Vidi, Posti
a not so normal vbb2 '64, a weirdo vbx '86 and a not so normal pts100 '82
Joined: 15 Jun 2009
Posts: 5488
Location: Indo
Sun Sep 15, 2013 7:40 pm quote
now thats look briliant Brother G
Member
a few shifters
Joined: 22 Sep 2013
Posts: 13
Location: antwerp belgium europe
Mon Sep 23, 2013 12:32 am quote
...
nice job............

quiet an idea for my gs 150 racer ( in progress....)
Enthusiast
125 TS VNL3
Joined: 21 Mar 2016
Posts: 62
Location: Greece
Tue Mar 22, 2016 9:56 pm quote
Re: Disc brake setup for oldie
Ginch wrote:
[/URL].
can u tell me about this fork? from what model? do you have anything about forks conversion and fitting on this model? great job though!
Molto Verboso
Vespa GTS 250ie
Joined: 02 Jun 2015
Posts: 1218
Location: San Francisco Bay Area
Wed Mar 23, 2016 8:32 am quote
If you wanted to keep the original handlebar look, you could use the original lever with a shorter cable actuating a remote master cylinder. The remote master cylinder wouldn't have to be from/for a motorbike, it would need to have the same cylinder ID however.
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7094
Location: Victoria, Australia
Wed Mar 23, 2016 6:02 pm quote
Kourabies if you read from the beginning you'll find the link that talks about the fork.

Fork Swap for 150 Super

I chose PX as it's cheap and needs very little to adapt it to the scooter - you can even leave it as is if you like.

You can do the semi-hydraulic conversion as SCTLVR says. I didn't do it that way because I think seeing the master cylinder on the handlebars is more natural looking than seeing the semi master cylinder on the fork. Plus I haven't heard many positive endorsements of that setup.
Molto Verboso
Vespa GTS 250ie
Joined: 02 Jun 2015
Posts: 1218
Location: San Francisco Bay Area
Thu Mar 24, 2016 8:58 am quote
The master cylinder can be located anywhere you can find a spot.
I did this on a build a few years ago and it worked great while maintaining the stock appearance.
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7094
Location: Victoria, Australia
Mon Nov 04, 2019 12:49 am quote
Recently I realised the stainless braiding on the hose was unravelling... also I was never that happy with the routing as it was a real pita to work on. So I got a new hose and hard line made up after a lot of thought about how it should disassemble. I'm very pleased with how it turned out. It was relatively easy to bleed, it's nice and neat, and even stays out of the way of my SIP speedo!

Several months ago I added an AF Parts brake carrier (was on special at LTH), it was described as a lower type. The very slightly flatter angle of the swing arm makes he ride feel more stable... tracking better I guess you'd call it. The radial brake caliper came from Aliexpress and is pretty good! It's exactly the same one as the Stage 6 caliper, except for the branding, and of course way cheaper.

20190903_181415a.jpg
Opened up a new hole so that the line was relatively flat and doesn't trap bubbles so easily

20190903_182233a.jpg
Pretty easy to undo the lines by pulling up the headset a little

20190903_182618a.jpg
It's a nice tight bend in there so it's right out of the way of the speedo. They did a great job making the hard line.

20190903_181940a.jpg
I chose a black flexible hose, which was thin enough to feed through the brake cable hole. And goes with the colour scheme!

Hooked
2001 LML 150
Joined: 16 Jul 2017
Posts: 324
Location: Melb, Aus
Tue Nov 05, 2019 6:22 pm quote
That's superb! Looking great M. Love the way there's a connection at headset - very nicely thought out!
Veni, Vidi, Posti
74 Super, 75 Super, PX project, LML off-roader and new to 2018, '66 Blue Badge Smallframe
Joined: 30 Nov 2011
Posts: 7094
Location: Victoria, Australia
Tue Nov 05, 2019 9:50 pm quote
Philos wrote:
That's superb! Looking great M. Love the way there's a connection at headset - very nicely thought out!
Cheers Phil!
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