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Front brake questions?

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McCabe-Thiele (Ted):
I've started fitting the front brake system together using a new DS master cylinder & all new pipes - so far I've just got the untightened flexi pipes in place with unions & copper washers.

First thing I've noticed is that the brake lever seems larger than the existing clutch lever - also why is there a lug on the master cylinder bracket that prevents it butting up to the switch boss?
I see now why some folk fit the bracket upside down but presumably there is a reason for the spacing lug?

Secondly the mudguard clip position on my new front mudguard is such that the steel brake pipe does not align as it should so at present will not fit. My first thought was to just make up a copper pipe that will bend into position much easier. Might be the mudguard bracket is not quite as it should be?

That got me looking at the clip / gromett situation - I'm minded to push the metal part of the flexi pipe into the gromett so its firmly held by the mudguard clip then make up the new pipe to suit the new position - not bothered about it not being as per factory fit - has anyone tried this?

McCabe-Thiele (Ted):
After a monumental struggle after a couple of glasses of red wine I managed to fit the gromett over the metal end of the brake pipe fit the steel brake pipe  bend the mudguard wire bracket and it all fits! Managed to head butt the handlebar end a few times due to mild intoxication but it's done!

Life is good.

TrickyMicky:
Hi Ted, what you have described here is a carbon copy of my antics earlier this year. My original fitment mudguard was starting to "laminate" across the bracing area between the forks, shame really because I had had it chrome plated to a far superior finish than the original. I had managed to locate and purchase (mortgage?) an original new guard and stays, still in its wrapper with the relevant part Nos.  The quality and placement of the cable/pipe guides left a lot to be desired, much cursing and bending was needed to make it all fit. I re-fitted my original re-chromed stays as the finish was far superior to the 40 year old "new" ones. And, yes, I did bang my head a few times on the end of the 'bars, but in my case the grape juice was used generously as medication.  Good fun ain't it!

McCabe-Thiele (Ted):
Strange definition of fun but yes fun!
The wine had been good medication but the asprin generated bruise will out me in the morning.

smoothoperator:
It's amazing how alcohol fueled engineering often works better than dry. The trick is to get just enough to be confident but not so much that you end up with a botched job. Just like the genius of many song writers although that was often coke or LSD, thinking of Rumours by Fleetwood Mac.

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