• Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

Brake Lever Mod

Kenneth Webb

Kenneth Webb

Livin' It Up!
This won't be for everybody, or maybe for anybody else, but I will be having a new brake lever waterjet cut so that it will be over-the-peg. It will look stock when done, but you will have to do quite a bit of fabrication to get it together. Anyone with welding skills or a welder friend might be interested. The lever will weld onto the stock boss, but you will have to move the master cylinder linkage tab up and weld it, and also weld a tab for the stock brake switch. The master cylinder push rod will need to be shortened and threaded too, or replaced with a shorter rod. Lots of messing around, but not all that difficult with a cut-off wheel, hack saw and grinder. The important item is getting the lever extension right and nicely cut. When I send the pattern out for cutting it's just as easy to cut two or twenty as to cut one. If anyone is interested, let me know and I can have extras made. It'll be several weeks before I get this to the shop to be cut, and I don't have a price, but for myself, what ever it is will be OK. The more I have made, the lower the cost will be per each. You could always get the lever blank and do the work whenever you take the notion or get around to it. A good DIY project for winter.

I have also ordered a BRP chain guide and will be fabing a bracket to mount it to the swing arm. I wish someone would offer this bracket for us, but it looks like a one-off.
 
You've got it. When I get the plates cut. I'll make up a sketch to show how I see it going together, though it is really self-evident. I plan on buying a morning, or day of welding at my fabricator and have the brake lever, side stand reinforcement and chain guide pieces all TIG welded at the same time. Just curious about your screen name; do you have a fab shop? If so, 'must be nice!
 
OK Kenneth, sounds good. I will await further instructions. I am surprised no one else has chimed in...it is a great idea and cost will be reduced with more made as you have all ready stated.

I do have a fab shop in the works. All tooling and welders have been purchased throughout the years, but the shop itself is almost done. It is small..24x24 behind our house. The size of the shop was perfect until I picked up my late fathers "14 x "56 F.E. Reed metal lathe. It was built in 1889 and is in perfect working order. I am going to have to build another out building just for it!
 
Well, most folks aren't up for cutting and chopping on their new bikes. But it's just metal and can be welded to be as good or better than before, and refinished, etc. And, custom low volume parts are expensive time wise. Still, these few mods are worth it to me.

Have fun with the lathe. I learned on a WWII LeBlond.
 
Looks like I'm going to need two of these. How we lookin? I saw you ordered up the Touratech shifter and it worked out good for you. Can you post a pic in the Farkels section? I ordered the 14 tooth sprocket from them and am pretty confident it will work as well.
 
I will get the drawing of the lever out to the water jet cutter tomorrow and see what the cost might be. You need 2? One for a friend, or did you go out and buy 2 Terras! If the cost is too high I will just cut by hand, but it would be a bitch. If you have access to a cad program I could send you a file, or if not, a template, if it comes to that. I will post up a pic of the new lever today too.
 
Here is what happened to the first Terra:

http://www.cafehusky.com/threads/pikes-peak-or-bust-ed-terra.28662/

I bought it back from the insurance company and sold it to one of my best friends. My replacement is on its way, so that's why I need two, one for him and one for me. I agree that if the cost is too high we can cut our own. Another option may be to send the file to a friend of mine to have him cut them out on his cnc plasma cutter. He made some recent life changes, so he might not have it any more, but we can cross that bridge later if needed.

Thanks ahead of time for posting the pic in the Farkels section. It gets a lot of views, but there isn't much there. I think a lot of people come to Cafe Husky who are non members to find out as much as they can about the bike. The ADV thread on this bike is just one thread and overwhelming. It is more organized over here.
 
hay am interested in the idea but what are you trying to achieve? stubby levers or easyer pull? stronger? lighter?
would have thought the clutch side is more of an issue..?
 
hay am just going to get rfx aftermarket brake looks like it will put me in the right area. around £30 quid so probably cheaper for you as your parts are better priced over there. keep us posted tho
 
juicypips said:
hay am just going to get rfx aftermarket brake looks like it will put me in the right area. around £30 quid so probably cheaper for you as your parts are better priced over there. keep us posted tho
Click to expand...

Which one are you getting? It doesn't look like any of them will work for the Terra only because the rear pivots are not low enough. Are you getting it for your WR or do you have a Terra/Strada?
 
actually neither i was going for my 550 zeypher but like the idea of clearance as i hate traffic an we have alot of lanes where im located so off road cutthroughs are possible.:thumbsup: am re building it over the winter and am using my kmx as a runaround. huskys in the shed keeping warm:rolleyes:
 
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