Brembo/Tokico Caliper adapter, 250 & 300 GB

[Bigballsofpaint]

Its not overly complicated, ive made things much more challenging. Im just trying to use exisiting fixturing and what not, and try not to do too many operations so it doesnt take as long. The extra material and extra time it takes to make them is the concern, im not trying to make a lot of money and want to make things affordable for everyone. Shark is going to send me a radial mount, im not sure which brand though and i will take it from there.

[sharky nrk]

^^^ Tokico off a 05-06 636 but that means the better Nissins froma 07-12 6R will fit as well, and probably quite a few others.

[rojoracing53]

Originally Posted by subxero

^ahh I c

I was actually under the impression that you were making mount for the tokico radial caliper. My bad.

@rojoracing53 had made a bracket to mount a radial caliper, It didn't look overly complicated. Perhaps he can chime in?

his thread is here
https://www.ninjette.org/forums/showthread.php?t=120310

here is pic from his thread

It was a limited edition run of only one so the rest of you are SOL sorry(not really)

And no I have no specs on the bracket to give you guys so it can't be quickly copied.

[Bigballsofpaint]

No big deal rojo, its not that difficult. But it looks like ill need larger material for that style.

I have everything ready to cut my first prototype (model and program done), material should be in tomorrow, so it looks like i should have something mocked up next week. Hopefully the first one is good and i dont need to make adjustments....

Also, for those following, since im actually doing it on my bike and need to go buy the screws and nuts, as long as the price is reasonable i will try to include them with each bracket.

[sharky nrk]

^^^ This guy ^^^^ BTW .......... Is awesome

[verboten1]

Rock on, I'm looking forward to the upgrade!

[sharky nrk]

So to make this even more difficult lol, when you look at mocking up the radial bracket for the stock rotor, could we look at it in such a way as to be able to put in some spacers and long bolts to run a 310 or 320 mm rotor? Gives the end user an even greater upgrade path to a bigger rotor later on?

Also as long as you flip the caliper over to bleed it, I don't see why you couldn't use the left side caliper flipped on a radial bracket.

[Bigballsofpaint]

Originally Posted by sharky nrk

So to make this even more difficult lol, when you look at mocking up the radial bracket for the stock rotor, could we look at it in such a way as to be able to put in some spacers and long bolts to run a 310 or 320 mm rotor? Gives the end user an even greater upgrade path to a bigger rotor later on?

Also as long as you flip the caliper over to bleed it, I don't see why you couldn't use the left side caliper flipped on a radial bracket.

You wouldnt need me for that. As long as its made with the 300mm in mind, the spacer you would need would be 5mm for a 310, and 10mm for a 320mm rotor.

[subxero]

Spacing the rotor between the pads/caliper might be important as well.

Stock rotor is only 4.5mm thick new? give or take? IDK? but regardless aftermarket larger rotors can be a good bit thicker. The thickness would obviously come into play on the clearance of the inside of the calipers right side as the bolt on side face of the rotor would remain roughly the same kind of like a zero point. the additional thickness of a larger rotor would then be seen on the other side, ya dig?

^ I think that makes sense, either way I know what I am trying to say

in short, make sure there is enough clearance on the inside right of the caliper to accommodate a thicker rotor

[sharky nrk]

well the stocker is really like a 296 or something right? so it would be a 2mm off, not a huge deal with the 5/10mm spacers but I meant it as more of a reminder to people looking into the GB/options. i haven't looked into the thickenss of the aftermarket "big rotors" for the ninjette so you may be correct on that one, nor have I actually looked into the stock rotor thickness of the 636 which the donor caliper came off of

[sharky nrk]

^^^ ok so just looked it up, 6R stuff was 5mm thick so as long as the stock rotor is centered in the caliper, no reason you could not run at least a 5mm rotor, and the calipers can accommodate a 5.5 as well (the 10R used 5.5 mm rotors)

[Bigballsofpaint]

Originally Posted by subxero

Spacing the rotor between the pads/caliper might be important as well.

Stock rotor is only 4.5mm thick new? give or take? IDK? but regardless aftermarket larger rotors can be a good bit thicker. The thickness would obviously come into play on the clearance of the inside of the calipers right side as the bolt on side face of the rotor would remain roughly the same kind of like a zero point. the additional thickness of a larger rotor would then be seen on the other side, ya dig?

^ I think that makes sense, either way I know what I am trying to say

in short, make sure there is enough clearance on the inside right of the caliper to accommodate a thicker rotor

I understand what your saying, but i just dont think an aftermarket company would make a thicker rotor unless thay made an entire kit. A different adapter would need to be made the change the centerline for different thicknesses, which can work, but then were just getting crazy here. I would assume the rotor thickness is the same, or within .5mm. I think larger than that would need the centerline moved. Like you said for on your brembo, you want the next version .020 thicker, which is your .5mm. You have no complaints as it stands now, and i guess no one else would either, but for future ones i would make it thicker to center it that much more.

You could measure your new rotor and stock one to see.

[Bigballsofpaint]

OK guys and girls, i managed to find a piece of scrap the size i needed. I didnt want to wait until next week to prototype this and good thing. Here it is

We start with my prototype to get my dimensions close


Onto the design now



And heres the part -



But there is a flaw, as usual with a first piece. Looks like i need to rotate the position of the bottom bolt back a little. It was biting too far down on the rotor, so ill bring it back a little. Easy change. It clears the caliper and all the holes line up. I feel the thickness is good too, it looked pretty centered to me. Now ill cut a few next week and ill send one out to you Rebecca to see how the 300 fit is.

[broken neck]

Jay,

Thanks for making this reality... We're getting somewhere...

Joe,

Thanks for initiating this project...

At least, my tokiko caliper won't collect dust...

[Bigballsofpaint]

No worries, it will be finished next week. I have all the info i need and the program proved out. Just need to make a simple shift. Ill make a few extra just in case people decide they want one.

[subxero]

looks great jay! What are you using on the inside to screw the bolts that go through the fork holes into?

[Bigballsofpaint]

Ill have to pick up some nuts, i may hit the hardware store today. I just put them in to see if my locations were correct.

[verboten1]

Dang, I didn't realize, but I may have one of those calipers!

[chugs]

Nice work!

[Bigballsofpaint]

Sorry for the late update, but i didnt want to post without information. Its all done! Here it is mounted on my bike, i will prob take it back off to paint it, but it sits good and bites the entire rotor with a smidge hanging off the back. The chamfers on the inside were alittle off but i adjusted them in the program. I havent run anymore since i just wanted to make sure this placement was good. Ill run more off next week, and ill get one out to Rebecca be the end of the week to verify 300 fit. I will include the bolts needed as well, but just in case anyone was wondering, i used 2 M8x1.25 x 45mm long bolts, with nylon lock washers in the back and a lock washer underneath the bolt (without it the bolt touched the rotor, and 40mm long was a little too short.) The stock caliper bolts actually fit the Tokico, so you can re use them for that.

[verboten1]

Perfect!

[Bigballsofpaint]

All set, for some of you at least. I already PMed Rebecca, so the first 3 on the list will be getting theirs as well. Ill PM you my information, and make sure to let me know your address in your reply. Ill try to get another 3 or 4 made this week.

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[Alex]

They look great!

[bruce71198]

With the amount of heat generated from the stock caliper I am wondering what the 4 pot will do to that tinny rotor ? Would it be easy to configure a bracket for the 320mm rotor?

[Bigballsofpaint]

if you want to use a brembo caliper i made an adapter for a 320mm rotor. If you want to use the same tokico, i would need a rotor to use, or i would need dimensions to go off.

[broken neck]

Originally Posted by bruce71198

With the amount of heat generated from the stock caliper I am wondering what the 4 pot will do to that tinny rotor ? Would it be easy to configure a bracket for the 320mm rotor?

Or you could use an EBC floater rotor with OEM size...

[broken neck]

Very Nice...

I can't wait to put that on my ninjette...

Time to order a rebuild kit for the caliper...

[N-m]

Very nice.

[Oxide]

i'd get one for $40, however my 500 has the rotor on the opposite side

[Bigballsofpaint]

Since i dont know if the fork and caliper placement is the same on the 500 i cant really say if this would even fit or not Oxide.

For the rest, a few members cannot pay until end of week, so i sent PMs out and update my list since Psych0hans wanted a brembo one as well. If any other members want this, ill only have 1 or 2 extra. After that, i dont plan on making more until we can get another group.

[Bigballsofpaint]

tftrocks, broken neck, verboten, and dj all shipped yesterday morning and i have PMed you.

Sharky and hans i should be able to get them done this week/weekend and get them out to you.

Since i didnt know shipping costs beforehand if you are not in the US i need to charge more obviously. It was an extra 15 to canada and an extra 20 to australia fyi. Let me know how they work guys! I still havent used mine yet, im taking it back apart now to pull the forks off....

[broken neck]

Yay,

Canada!

Stoupid borders...

[dandj86]

Payment made and PM sent, thanks heaps Jay!!!

[gantt]

Not trying to thread jack. But a lot of people in the know with calipers visit this thread. Any advice on the front tokico caliper from an ex650?? I have an extra here I could use if its worth it.

[subxero]

Originally Posted by gantt

Not trying to thread jack. But a lot of people in the know with calipers visit this thread. Any advice on the front tokico caliper from an ex650?? I have an extra here I could use if its worth it.

why don't you do some research and find out if it is the same as the Tokico he used to for the bracket?

[verboten1]

Originally Posted by Bigballsofpaint

tftrocks, broken neck, verboten, and dj all shipped yesterday morning and i have PMed you.

Sharky and hans i should be able to get them done this week/weekend and get them out to you.

Since i didnt know shipping costs beforehand if you are not in the US i need to charge more obviously. It was an extra 15 to canada and an extra 20 to australia fyi. Let me know how they work guys! I still havent used mine yet, im taking it back apart now to pull the forks off....

Thanks man, I have found a couple different calipers here that I hope will work, if not, oh well! Better brakes on everything!

[DeltaFoxtrotZulu]

So definitely up for this if there is a possibility of getting one. Got the tokico already.

[Bigballsofpaint]

Finished the rest of them. I had 1 extra but Delta has dibs on it as long as Rebecca verifies the 300 fitment. I will ship them early next week. Sharky, i recieved your radial mount tokico, i can def make one, but its going to take some time since now my bike is back together for a track day next week. It will also be a decent amount longer and thicker to accomadate. I may have to charge more due to the extra material, in the 60 -75 shipped range depending on a GB and all that jazz. Once i verify my bike actually works ill start figuring out a design for that. Ill PM the rest of you my information today at some point when i get a few minutes.

[broken neck]

Just got mine today...

Now need some time to install everything...

Thank again, both.

[tfkrocks]

Unfortunately I don't have an ETA on when my brake caliper will arrive because all tracking stopped once it was forwarded to my new address by USPS. I would have received it before the bracket had the package not been forwarded. Hurray for the postal service.