yes we're here in the frozen north that's that's where we are we're in canada eh hi
i'm paul brodie we're in my shop here you're the viewer me mitch operating the cameras
we're back on on tiger cubs there's a psychic cup right behind me here and today we're going to work
on the brake pedal i have three brake pedals here look at this fine piece what a abomination this is
anyway i guess somebody you know put some effort into it and cobbled it together out of whatever so
i've got a nice piece of metal here it's one quarter by three and a half it's cold rolled
we're going to make a brake pedal out of that so that's the plan for today
in the meantime what's new i want to show you what's new in my shop i have something over here
my friend mike i've known him since he took frame building 101 he made me an excelsior lamp
very nice mike has a youtube channel he's a real smart guy and so i think that
mitch is going to show you the link and he he has a video on how he made this lamp so it's
an excelsior head it's a rear head it was one of the ones that was extra to me so thank you mike
that was a very nice christmas present all right so the brake pedal let's see what we can do here
i went down to my local cycle salvage shop it's called super sport and i got a brake
rod this was the only one that he had in the shop he had he used to have a whole bunch of these but
they don't sell now so they all went to recycling that's the problem working on all the bikes now
it's getting harder and harder to find parts so this is often 0-4 honda 600 shadow i believe so
i'm not going to use all this but i'll i'll definitely use this part of the brake rod
got some nice tubing here i got some bronze these ones here have no bronze bushing so it's just
metal on metal steel on steel so we're gonna add a bronze bushing there's a light that has to go
in there at some point but i think the first thing you do is to put on the foot peg rubbers
because the petal has to rest underneath this is just a little bit of hand cleaner
nothing high-tech and then it just dries up
okay that looks good so this piece here
goes into that hole there and this is where the pivot is for the brake lever
yeah like that so you can see what's going on here
oh i see why they bent it see that that's i don't think that's a stock bend that looks terrible but
when you put it on that's about the right space there so what we have to do now is to make up
a tube here a tube and the tube's going to be made out of
this piece of tubing it's seamless it's dom and then there's a a bushing is going to go
inside there so one of the first things we can do is to machine this down a little bit
make it the same length as the shaft there so what also i want to show you is this i don't like that
but we have to choose one of these and which one's better
i know what i'm gonna do i'm gonna bead blast both of these and then we can see
what they look like a little better so we'll just pop over to the bead blaster right now
i think i like this one better
that's what i think it's the pad on the worst pedal
let's use that one because this this pedal is awful
oh there we go look at that okay that's my new pad okay this is the tube which becomes the part of
the brake lever and it gets welded into that into that plate and then the bushing goes inside here
okay we have it too so let's go and
work on a shape now so if we drill a hole right right there something like that
that's where that will go and then i can trace around that that doesn't work does it not
oh
that's a good fit this needs to be level i don't i don't think my
foot ever goes like that if anything it goes a little a little bit down
this is too high and it's kind of awkward to have a stop here with a bolt that comes onto the
rubber peg it's better just to make it right from the start this is approximately level like that
okay so that'll go like that
so
it's going to need a bend somewhere so i think we'll have this
almost out to the edge there then it has to bend here because it has to come
under the peg and right now it's hitting on the actual metal here
i think that's the bend area
oh yes
so we have to let that cool a little bit and then we'll see how it fits on the bike
and then i probably have to make an another bend here to get this piece in line see how this is at
an angle i want that to be straight up and down so we have to give this a little bit of a twist
it's got a bit of a funny kink in it i guess
i don't know if you're really gonna notice that on the bike or not
yes we're here in the frozen north that's that's where we are we're in canada eh
can you see how that's a funny shape that's not not exactly what i had in mind but
i've got an unbending machine here that's this is what i'm going to call this and we'll
we'll take out the
bend it's like starting all over again that looks
nice all right we're trying a different method now maybe i won't use heat this has already
had some heat in it not that that makes any difference but let's see what happens here
okay so it's got a little bit of a curve to it that's a lot nicer a lot nicer than last time so
it's good to work with steel steel is pretty good stuff
okay i'm glad we fixed that up a bit because that's
that would bug me if i had that weird shape in there so this is much better
i don't have the right size reamer i got 437 and the shaft is four three three five
so we're under by three thous so what i can do is to increase the od so it gets more of
a press fit and then it shrinks the id it's kind of a gamble how well this works out so
i'm going to do something which you almost never see me do i'm going to part off
in the lathe i know you think i always use a hacksaw
so you see that it fits on there right now but it's a little bit loose can you see that move so
what i'm hoping is that when i i press this in to the brake lever that the fit becomes really good
and if it's not that good i can sand the inside just a touch let's go to the albert press so
oh it's got some it's got some press
oh yes definitely got some press to it so
and then that's gonna go like that super
if i take out a little bit of metal right there
and right there that's going to fit on there quite nicely
okay
okay i'm happy with that
i was thinking of using this piece here because it's that's hard to bend
just like that if i was to cut this piece off about here
and weld it on to
there
that might work should we try that okay
there we go i sent mitch out for more coffee and while he was gone i did some work on the
bike so let's have a look at what happened i worked on the on the brake pedal i welded
this up i made a little piece here this has to be silver soldered in i don't have a spring
well i've got springs here there's nothing that's suitable what's going to happen is the spring is
going to get held somewhere here and speaking of this i'm not very happy with this at all this is
i altered the other side to hold the exhaust and i like that this is almost in the way
all this big thing here has to hold is a spring and a brake light switch
what's supposed to happen is that's where the foot pegs supposed to go for the passenger
if i put this in can you see how it angles down it's terrible so i might have to redo
this it's not going to happen in this episode for sure i made this yesterday i took a piece of
uh of cold rolled half by half i like it it's kind of nice a little bit of flux
and we'll get some flux down here
so a lot of heat's going to go into the abutment of the boss whatever we're we're calling it
if i heat it up we'll see if it comes through that would be perfect
i'm a little sloppy with the rod today
and i'm supposed to have a spring here but i won't put that in right now we're just gonna
we'll put on this nut i'm gonna make a fancy one i don't like this it's off a honda after all
so let's see what happens this is the first time the brakes getting used
oh it does spring back look at that it's got a spring inside there for the shoes
it's not coming back all the way but i am going to have an extra spring here
and i i want that in line and i think this is going to get this is going to get modified this is
don't like it okay so there's the break we have an almost operational break on the tiger cup
thanks for watching that was pretty neat project i liked it took a lot longer than i
ever thought mitch and i like coffee if you buy us coffees much appreciated see you next week
i also got the side stand mounted and that turned out quite nice look at this
there's almost zero slop i use chain lube i use loctite on the thread and then when
it was assembled i i gave it a shot of of chain lube because that goes right in