Now, onto the duc. Solving the rear brake has left me scratching my head for some time. So I figured best to just dive in and figure it out on the fly. I had a working brake in the wheel hub, a cable and a tab on the left rear set. I just had to figure out how to tie it all together. Originally I was going to weld a small piece of tubing to support the cable. But then my neighbor Craig suggested using a small piece of triangle to better support the cable end. Brilliant! lol.
I drilled a hole in a small piece of steel tubing and tapped it to M5 to act as a cable end catch. I then welded a small piece of steel to it to mount to the rearset eyelet.
Next was to fabricate a support for the cable to weld to the frame. This had to be robust as it would supporting the downward force of my foot pressing on the pedal.
This is where the triangle idea came into play. I measured some rough dimensions and was sure to leave plenty of excess that could be trimmed away. I welded two pieces of angle together at 90 degrees. I then welded a third piece of 90 degree L bar to support the end of the cable. In this L bar, I drilled a hole for the cable to be routed through.
The cut away piece is just wide enough to allow the cable to pass through, while the hole is wide enough to catch the sheathing.
I trimmed the lengths as necessary and filed it down to ensure everything was straight. From there I welded the assembly to the frame and made the final adjustments to the cable. In the end, the assembly fit and works perfectly!
Here are some pictures of the final product!
To finish up the evening, I welded the mounting tab to the top of the rear fender. Everything is buttoned up and I am one step closer to kicking the motor over for a ride!
The next steps will be to sort out the front end and wrap the exhaust system. A box from JC Whitney should be coming tomorrow, so I will eagerly be watching for the FedEx guy while doing homework.
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