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Suzuki Intruder VS 1400

This is a discussion on Suzuki Intruder VS 1400 within the Project Builds forums, part of the Caferacer.net Forums category; Originally Posted by o1marc I had the same issue mounting Tokico calipers to mine. I was fortunate in that the lower legs on a triumph ...

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Thread: Suzuki Intruder VS 1400

  1. #61
    Senior Member MarkHarold's Avatar
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    Quote Originally Posted by o1marc View Post
    I had the same issue mounting Tokico calipers to mine. I was fortunate in that the lower legs on a triumph are steel so it only required a single bracket made and welded on. In your case just put the caliper on the rotor where you want it and pressurize it to hold it in place while you use a piece of card board to mark your 4 hole locations. It's a piece of cake from there making a bracket and spacers.



    My calipers are Tokicos that I shaved the name off and put the Triumph logo on them. I was going to use the same 6 pot caliper you have, but they are too wide on the backside and would have hit the spokes.
    Thats a neat setup you've got there Marc, I'm not brave enough to think about welding a bracket to the fork. Replacing the Tokico name with Triumph is taking attention to detail to an unknown level to me, so top marks!
    The bracket for the little Tokico will be neat enough, hopefully I can do something decent with the 6 potter.
    Last edited by MarkHarold; 02-07-2017 at 02:40 AM.
    Cheers, Mark
    Struth! Stone the crows and starve the lizards.

  2. #62
    Senior Member MarkHarold's Avatar
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    Quote Originally Posted by TrialsRider View Post
    Those zip ties are never going to hold

    You're attaching a cast aluminum part to a cast aluminum part and aluminum is a lot easier to shape and work with, ... I'd go with aluminum. Stainless looks nice in raw form but unless you have to make the parts super thin I'm not sure what the motivation would be.
    I did end up making the bracket out of aluminium, the scrap man had no stainless but did have some 10mm and 5mm aluminium plate, and it is easy to work with, so thanks for the advice.
    Turning scrap into a work of art.
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    The bracket consists of 3 parts, 10mm plates that bolt to the fork and caliper and a 5mm spacer between them. I decided to bolt them together with 3 10mm stainless bolts with nyloc nuts instead of welding, I was concerned welding would warp the plates. Hopefully the brackets will not get hot enough to melt the nyloc nuts. It all lines up and is as compact as I could make it.
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    Now I'll make the bracket for the 6 piston caliper.
    TrialsRider likes this.
    Cheers, Mark
    Struth! Stone the crows and starve the lizards.

  3. #63
    Senior Member 8ball's Avatar
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    Quote Originally Posted by o1marc View Post
    .... I was fortunate in that the lower legs on a triumph are steel .......
    That's probably the first, and ONLY time that statement has ever been issued!
    Stephen J likes this.
    I always find a soap box useful to get on my high horse.

    Quote Originally Posted by roccitycafe View Post
    .... same thing with furniture, it doesn't have to be straight or not wobble, or keep thing from rolling off it, or not collapse when sat upon, it's personal taste man... if I want a dining room set that endangers the life of my dinner party guests, then it doesn't need second hand approval

    My GS550 Build Thread

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  5. #64
    Senior Member MarkHarold's Avatar
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    I've got a feeling that the 6 piston caliper may be an over reach, but I'm happy with the fabrication. I've ordered a stainless braided line, I will wait and see how the existing master cylinder performs, I will surprised if it drives the 4 piston caliper, and amazed if it drives the 6 potter.
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    Now I will get back to work on the exhaust.
    Cheers, Mark
    Struth! Stone the crows and starve the lizards.

  6. #65
    Senior Member hillsy's Avatar
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    The pistons are smaller on the 6 piston caliper compared to the 4 piston so if the MC works on one it will work on the other.

  7. #66
    Senior Member MarkHarold's Avatar
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    Quote Originally Posted by hillsy View Post
    The pistons are smaller on the 6 piston caliper compared to the 4 piston so if the MC works on one it will work on the other.
    The original brake had deteriorated over time, it became very spongy, I think mainly due to flexing of the line, so I'm expecting the new stainless braided line will stiffen things up, it's most probably just as important as the upgraded disc and caliper. I'm interested in seeing the difference between the 4 and 6 piston calipers.
    Cheers, Mark
    Struth! Stone the crows and starve the lizards.

  8. #67
    Senior Member MarkHarold's Avatar
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    So much for 6 piston caliper, when I split the caliper to clean it I found a severe scratch in a piston, so I took it back to the spare parts man. I've ended up with the very first caliper I tried, the wheel has turned full circle but I've gone nowhere. At least I can use the same mounting bracket, the pads don't line up as well, they could be moved out a couple of mm, but I think it will be OK.
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    I'm a bit frustrated with my lack of progress with the exhaust, I can't find the right guy to do the bends. The guys with the big flash machinery want me to make them millionaires, I'm looking for someone with a manual bender. Being a pound stupid penny wise sort of guy, I can see myself buying a bender, there is a 1 5/8" die on eBay at the moment, but I want 1.75". Decisions! Decisions!
    Last edited by MarkHarold; 02-27-2017 at 02:35 AM.
    Cheers, Mark
    Struth! Stone the crows and starve the lizards.

  9. #68
    Senior Member brad black's Avatar
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    not sure if ken at megacycle can help.

    i have had some custom bends done by a place in qld called beaudesert. they seemed pretty cool about doing what i wanted from sketches. Welcome - Beaudesert ExhaustBeaudesert Exhaust | Leaders in quality 4WD mandrel bent exhaust systems. Designed to improve power and fuel economy. Specialists in supplying custom mandrel bends. Supplying Most 4×4 Toyota ? Landcruiser, Hilux, Prado, FJ

  10. #69
    Senior Member MarkHarold's Avatar
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    Quote Originally Posted by brad black View Post
    not sure if ken at megacycle can help.

    i have had some custom bends done by a place in qld called beaudesert. they seemed pretty cool about doing what i wanted from sketches. Welcome - Beaudesert ExhaustBeaudesert Exhaust | Leaders in quality 4WD mandrel bent exhaust systems. Designed to improve power and fuel economy. Specialists in supplying custom mandrel bends. Supplying Most 4×4 Toyota ? Landcruiser, Hilux, Prado, FJ
    Hi Brad, I want to find a guy around Melbourne if I can, and I quite like the idea of having my own bender. Something will turn up, I'll keep looking for another month. I've met some real nice blokes, as well as some others. The last bloke I talked to wanted $600 to set his machine up. Yeah, right mate.
    Cheers, Mark
    Struth! Stone the crows and starve the lizards.

  11. #70
    Senior Member MarkHarold's Avatar
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    It feels good to make some actual progress, the welding on the tank is now complete, barring any leaks. Tomorrow I will rinse it out with phosphoric acid and if all OK, prepare it for painting. I've bought a can of etch primer and a tub of filler. I think I could have done a better job of slicing and dicing, especially around the front, but at least it's back in one piece. The filler will cover my sins. I'm having second thoughts about the second tank, but that's way in the future.
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    I've more or less accepted that I will have to go to a professional mandrel bender for the exhaust. I did actually buy a tube bender, but when I went to pick it up I noticed that the die section was oval, not a semi circle as I expected, and the seller offered to cancel the sale, which was very good of him. He advised me that I have to go mandrel, so, so be it. But then I wonder how hard it would be to fit a mandrel, I think it's possible, but I still need a bend die with the semi circle section.
    Cheers, Mark
    Struth! Stone the crows and starve the lizards.

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