DIY disc guards

Cam's front brake and Ali's previous bike's rear brakes were held by zip ties. Should work.

This is different can't be bothered explaining if you dont see why but I won't be using zip ties

I'm up for making something as well, Rob and Ste i'll chat to you this weekend in Bristol about it. You can explain this dremel thing.

If you gave me a design, and paid for the materials in advance I could do them for you. I'm busy all next week but should have time afterwards. See how a few of you get on with them, make minor adjustments if need be and make some for others.

You've never dremeled Rich? Pish.
So Moog is going to help mock up these in 3D if I can do a design. Brickman would still do the machining but it would be helpful to know what the material is and how much.
We'd need to decide on caliper cover or not and come up with a universal fit.

I would like to point out that Max Power's new one with caliper cover is awesome and a great price. Ask him for pics.
If you can adapt it for your bike then cool, but it won't fit mine.

Ste fucked up his hand so we've not done it yet, will probably be doing it next week.

I'll still take a front & rear off you.

Wicksie - Any chance you could send me your sketches?

Sure, see this post:

PDF of design attached.

Do you have illustrator?
Am looking for the caliper one.

Here's the rough calliper cover one.
The actual template would need to be expanded to include the bevels. And again, this is made to fit my NS traffic.

1 Attachment

• calliper cover.pdf

I'll have a look over the weekend and get back to you about it asap

RE: sheet metal bending. have various size hand operated presses, and a very very large hydraulic bender (18tonnes/inch?) with various toolings for it. So can bend just about anything.

Material wise, just had an epic clearout at work, and most of the small (free) offcuts of alu sheet (3/5mm) have gone. Have a piece of ~5mm alu sheet approx 300x400mm sat here (should be able to do 2 or 3 items?) thats supposed to be 6000 series of some sort.
I think you'll find 5mm for the 180mm sized rotor pretty damn weighty.

Awesome Brickman, thank you!
The other guards are in 6mm, unless T6 6061 is lighter than this?

So, how much are we talking? Lets assume we do 10.

The rotors are 160mm btw. I've assumed that's universal for polo.

I'll still take a front & rear off you.

And me...

If poss, otherwise I'll just get a couple off Max...

Anyone got a picture of their front brake I could use a base for designing this?

Sorry I keep dropping the ball on this one. I've been meaning to do a design but things are quite hectic for me in work at the moment, been swamped for the last two months, dont have the same time that I used to do for catching up on things... if Wicksie's design is generic that it can be applied to other bikes with minimum of messing around then I'm happy to take a copy of what she's having and then drill it if necessary.

The only problem I can see with Wicksie's design is compatibility with other bikes. Mainly due to the bike she's using being a jump frame having a small rear triangle. If the section under the chainstay is made deeper then people may be able to cut it down to fit their frames exactly.

If other people upload pictures of their rear disc mounts it should be easy enough to make one compatible with most frames.

I jointly run a bike shop in Birmingham and we get a lot of stuff machined for us at a local workshop.
I've just spoken to the machinists and they're keen to make some guards (being cyclists themselves).
Probably around £15 per guard (material + labour) for 4mm 6061.

If we can get a template it will be very easy, otherwise we'll have to set it up from scratch.
Hopefully try and get some prototypes done for Cambridge BM.

Anyone interested before we go ahead?

I've got a medium Pompetamine, same geometry as a Pompino IIRC...

If you guys want to hold on, then I'm collaborating with Moog who's doing 3D design at Uni. This might take a while so feel free to use what I've drawn up so far if you're in a hurry.
But bear in mind that these are the first 'sketches' and I've just drawn it over my (DJ) bike and with a 160 rotor. I think most people use 160's but it will need tweaking to fit your bike, or I'll need to come up with a 'generic' one, which will take more time. Also it's a 'flat' sketch so hasn't factored the bevels.

Obviously the front guard will be universal but I don't have one so need a decent picture before I can drawn one up. Can anyone hook me up?

We might well be interested Hyper Allah, just need to hear back from Brickman on what material and how much I guess.

I can't submit my frame yet as I don't have it yet, will wait
Until built before submitting. I think it will be similar to a pometamine.

Right, boss free day tomorrow, rotor's will be drawn.
Just discovered you can save to CAD in illustrator /csb

Can someone please get me picture of the front brake?

Here's the rough calliper cover one.
The actual template would need to be expanded to include the bevels. And again, this is made to fit my NS traffic.

Looks like a grumpy alligator.

Got a rear prototype being made up. Front to follow, just need to borrow a mate's bike at polo on sunday. Will post results.

(I use v brakes wicksie so can't post any pics)

Who's gonna make front ones? That's where it's at!