On reflection the standard bros brakes were a bit naff so as I mentioned before it was time for a modern upgrade, I removed the lugs that mounted the original calliper and have made a bracket to fit the new calliper from a Suzuki Hayabusa, I won’t be attempting the welding on this part of the project as I have no way to join aluminium other than jubilee clips and nails so I have handed the parts over to Stable fabrication in Towcester http://www.stablefabrication.co.uk/ , great bunch of chaps who will have a go at anything within reason for very sensible rates. – Heisenburg.

I collected the forks from the fabricators yesterday and was very impressed with the welding job, very neat!

Tonight I managed to find some time to start putting things back together, the weld had penetrated inside the tube a little and distorted the inner wall so much the stanchion would not slide inside the leg anymore, I hadn’t even thought about this happening but managed to fix it easily, I made up a 38mm aluminium cylinder with a thread in one end to take about a foot of threaded bar, this went in to my drill, the other end I hacksawed a cut and attached some 400 grit emery cloth, I reamed this in and out of the fork leg for a few minutes with some thin oil and it all fits quite well now.

Next job is to finally start the yokes, I have a bit of an odd design in my head but it should be fine, I’d prefer to go the normal route but I couldn’t blag the right size of aluminium slabs for free so second best will have to do. – Heisenburg.