So I had a fully functioning dual disc set up. But somewhere over the last 15 years of the parts just sitting around, I got something mixed up and upon reassembly, the addon caliper wouldn't line up with the disc. Rather than discover what I've done (probably swapped a hub) I've opted to make it fit. So first step is to cut down a lug from the fork leg. By removing about 3/8 inch, it will bring the caliper 2/3 of the way. I thot it would need a machine shop, but then I thot, what about a hack saw? I taped off the fork leg to protect it from scratches and went to work.
Amazingly, I made the cut nearly perfectly. Here's the lug I cut, the leg is very soft aluminum. The lug above gets a spacer. The bracket needed additional relieving to clear the fork leg, done with a grinder and file. It mounts flat and swings clear.
Now I'll have the machine shop chew on the caliper a bit and it will line up perfectly.
You can see how the caliper bracket is not in the same plane as the disc.
Next is a trick many of you know, but a few may not. To remove and install a sidestand, or centerstand, spring, move the stand to the position which stretches the spring the most. For the sidestand that's about 4 oclock.
Then push shims into the coils. Some say pennies work. I used strips of alumium flashing.
Then when you move the stand to its down position the spring is easy to remove or put back on.
From some parts sales and OT, the treasury is in good shape. Time being more important than money, at least for now, I'll send my tank to Boyers Tanks to be treated and primed.
My buddy has THursday off, so we'll remove the entire front end en masse and haul to Saldana Racing Products. They'll make the fork brace/fender mount, modify the caliper and make a mount for the air fork filler.
Then... the engine.
