Very good job!

I contacted a place that does heat treatment yesterday. They said $40 and ill have to ship it to them. I started on a hub but haven't had much time this week to mess with it.

Built my hub today. Still have a bit more to do on it. I believe the rotor is for a buell 1125. It's the same outside diamete. The area of braking surface is slightly narrower than OEM pads. However I did find some pads with narrow material. This should fix this issue. It would only hang over a 1/16" on the inside anyway. So I could probably run regular pads and be fine.

That's beautiful work.
Question --- that was a hell of a lot of work but could you have just the stubs off the end of the stock shaft and run internal splines ?? Or were you trying to keep that old shaft ??

The issue with that is the splines and threads for the brake rotor on the original shaft is too small. It would be paper thin. I believe that's what Farr had done here viewtopic.php?f=5&t=14515 if you look at his he had it chopped and EDM'd out. But since he now has no splines for a brake hub. He has to run outboard brakes. And it will offset the left side axle shaft inward about a inch. I wanted to retain the factory brake system. It's a lot of work but its my project not something I will be mass producing.

I see.
My formula race car had inboard brakes and it puts a hell of a lot of stress on the axel. In fact it would snap the axel bolts (mine were bolted not splined like yours will be). Outboard brakes would put less stress on those axels. Anyways you answered my question so thanks. Nice work.

I had considered building outbord brakes. But then I thought if I keep adding more things to this ill never finish it. It's been on my bench for over a year and a half. And I'm dieing to get it finished up.

Blueprint your parts maybe someone else will be interested in mass producing them? work looks good!

Outboard brakes adds sprung weight, probably does not matter on a automobile used on road.

I have them on my phone. I'll post it soon.

I was also thinking about how much stress is put on the gear box by having the axle a suspension link. Ever grab the rear of your Odyssey and shake it side to side? All mine have at least a 1/8" of play. I think this is also why the caliper and brackets wear so quickly. With every uneven bump its traveling back and fourth. So just by releaving the stress from the suspension on it. It should be a huge increase in strength and durability.

I learn more every day about these machines.

I'm looking for some brake rotor studs. And I'm not having much luck. Anyone know where I might find these individually?

get some arp wheel studs ?

I'll check with them. I need to get back on this project. I've been busy lately.

Any more on this project ??
As well as Hoser's comment above ??

I still need to send the shaft out for hardening. hope to do it soon. I have a sketch of the shaft with the dimensions but I left it with my friend who was helping find a machine shop to build the shaft originally. I just got to remember to grab it next time I'm down his way. When I do ill defiantly post it. I did intend to work on the back section of frame over the weekend but the tubing I thought I had was the wrong size. So I spent all weekend working on my pilot instead.

finally scored a pilot controller for this project. its pirty rough, but will clean up nicely. i got a good deal on it.

the pistons were seized. i drilled and tapped them 1/4-20 and extracted them with a piece of all thread, a washer and a nut. the bores look good. i ran a 1/2 ream down them just for clean up. the grips came off easily after soaking them in hot water. i found complete replacement sight glasses these are the no glue press fit oem type. i am missing the levers ill have to order a set of those.

Me too, ditto! Check your emails please sir when you can

ok it took some digging but i finally found a picture of the diagram i drew up. its not very good but it gets the idea across. the new larger disc brake rotor hub splines are the same as the inside external splines for the final drive gear. i used the retaining nut fron the 350 crank shaft. the hub i also buit from scratch. the rotor is from a buell 1125 and has the same outside diameter as the stock rotor. it is slightly thicker. i don't have a diagram of the internal splines. i took all dimensions from the old shaft and cv axle in hand and test fitted as i went. so again this is just a guideline.

Lookin good anyhing new?

May i ask where you obtained the sight glass?

Sure here's a link. They look identical to the OEM glass. I haven't installed them yet. There a press fit. But just setting them in the hole I can tell they will fit nicely. I also found these on eBay but there $15 ea. And I had a amazon gift card http://www.amazon.com/Premium-Scooter-M ... B00J4Z9JPO

As for my project. I haven't had much time to mess with it lately. I hope to get the steering controller and master cylinders to the chrome shop this week. I will defiantly post some pics when that's done.