This afternoon I finished bolting on the front forks. To accomplish this I needed to uses various parts cannibalised from other bikes. I then installed the clip on bars. Im not totally happy with their height but I can worry about that later. I installed the disc brake lever and the old throttle cable but really I need a new one.
The bike is really coming together now. I still need to install the rear brake lever/cable, bleed the front brake, pump up the tyres and work out how im going to install the front mud guard.
Test ride coming soon!!!
This evening I broke down the old Tomos front end. I removed the front tyre and installed in on my new front wheel. The front end is now complete! I started installing it onto the frame but ran out of time tonight. As you can see the forks look too long compared to the old ones so I will need to slide the tubes up into the yokes until it sits at the right height. More to follow tomorrow.
This evening I made the caliper mount out of a piece of angle iron. I had to do a bit of grinding to make it fit properly but was pretty straight forward. I still need to add a few washers to get it lined up properly. Next I'll bleed the brake and fit the tyre.
Today I offered up the caliper to the disc rotor and was able to slip a bolt through the existing bracket. Im planning on cutting a piece of metal (shown in red) to bolt between the existing bracket and mounting holes on the fork leg. This will hold the caliper in the correct possition.
Today I was working on the disc brake for the Tomos. My goal was to get the wheel centred on the forks without anything rubbing. I used some washers and spacers to get the wheel centred but the the disc rubbed on fork leg and so did the nuts holding it on. This was due to the disc not being flat but offset. I decided to flip the disc so it would be closer to the wheel and also reversed its nuts and bolts because the bolt heads were 2mm shallower than the nuts. I put it all back togther but still needed to grind the fork leg slightly to give the bolts heads extra clearence. Its all straight and runs smooth with no rubbing. Next is to make the caliper mount and fit the tyre.
Today I got the disc mounted to the Tomos wheel. First I used the rear sprocket spacer to mark on the disc where the new holes had to be drilled. Then I drilled the holes which took absolutely ages. Once id finished drilling I used M7 bolts with nylock nuts to bolt it to my old rear wheel which is now my front wheel. Next I need to order a 12mm axle and make a bracket to mount the caliper.
Just a quick post to show you guys the disc brake rotor offered up on the tomos wheel. I need to redrill the holes in the rotor to match the holes for the rear sprocket then bingo! A disk brake wheel :-)
Just did a quick drawing of the mount I need to make for the tomos. Im going to cut up and use old mower blade as its a decent thickness so should be strong enough.
The disc brake caliper arrived today for the tomos. Its the same one I used on the Peugeot. I offered up the wheel to the forks and measured out to where the edge of the disc will be when it arrives. Then I attached the caliper by one bolt so I could rotate it till it sat at the right distance and angle from the axle. Next i'll make a cardboard template to mount the caliper to the existing holes on the fork. Once ive got the template right I'll cut it out of 5mm steel plate then drill and tap the holes.
So yesterday my new pair of forks arrived for the Tomos. I found them on Ebay france. The are actually for a peugeot 103 but I can adapt them to fit. The most important thing about these forks is that they have a caliper mount for a disc brake. Im going to build this new front end off the bike and when its finished I'll install it.
