DIY disc guards

I was thinking if you wanted to portray the caliper, have some kind of 2 part guard, one part being the circle and a mounting block that mounts to the brake holes, that way the circle could be flat.

Depending on the thickness this would be quite easy to machine at home. 4mm should be fine, no? 6082 Alu can be bought to size online quite cheap - 4mm x 160mm x 160mm is £1.60 from here http://www.aluminiumwarehouse.co.uk/ Make the design in wood or plastic then use a router to trace the shape. It's how I'm going to be replacing the broken spider on some cranks I have.

If I had the time and the money I would make these for people, probably even slightly custom due to different frames.

^^ true, I might just make my own with a drill and hacksaw

Dremel!

Yeh! Rob if I get some sheet alu can we dremel them together?

yeah! We'll dremel the shit outta them

how big for 4 guards? disks are 160 each so if i get 400x400 sheet 4mm thick?

ok was gonna order 4 200x200x4mm T651 plate - £2.50 per guard

however £14 postage (standard charge regardless of amount) so would be £29 will get from somewhere else

400 x 400 would be good for 4, I'll look at making some card ones tomorrow. 4mm is probably thick enough, 6mm might be a bit much for the dremeling

1. Dublinkev (when you say pair, you mean front as well? I'd probably be in for that too)
   
   

yes front and rear for me please. On a phone on a train now, going on a small holday so will try to feedback more next week

Considering the cost of that sheet metal I'm just going stop round my local metal merchants.

Yeah right, dremel time, why not.
Here's a crude template for 160's if you want it.
The astute amongst you will notice an accidental genitalish shape in this, and an intentional one in the previous.

PDF of design attached.
I'd double check the mount holes, because it's a crude design and I've had a beer.

Post pictures if you get any made up.

Brickman, I'll be in touch next week.

1 Attachment

• rotor.pdf

Cool, it's like pacman got beaten up

looking good, managed to order the alu from ebay with cheaper postage 400x200x4 is £12 with free postage so il get 2 lots of that £6 per guard, that cool Rob? dont wanna order a 400x400 sheet as i wouldnt be able to bring it round on my bike!

also thinking some kind of jubilee clip on the other end to attach to the frame
or a coster brake clamp guess we can just make on of those too out of thinner stuff

http://www.sjscycles.co.uk/p-clip-rubber-coated-black-per-pair-prod5058/

would it not be easier to just make an adapter out of alu to mount an old rotor? It would be lighter..

would it not be easier to just make an adapter out of alu to mount an old rotor? It would be lighter..

maybe but would need 2 old rotors (that i dont have) and these will look cooler

I've got some old rotors, if they we're attached properly they'd be alright, the problem it looked like Ste had last time he hacked one one was it was a bit flexy if only mounted to the disc tab, I'd of thought the cut alu could be a bit stiffer. I just want to dremel shit really, always fun

http://www.sjscycles.co.uk/p-clip-rubber-coated-black-per-pair-prod5058/

Prob too small for chainstays

Zip ties

Zip ties

No too much movement, tried that last time

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

Zip ties

i've broken my calliper in quite a short time, i would definitely want to protect it.

I bought a max power one for the front that will protect both rotor and calliper. However he has mounts on his design of forks to attach it to, so i'm just going to solder a nut to my forks or drill and tap them (it's thick alu).

But for a steel frame, brazing (or soldering, with a propane torch DIY) a nut on to the chainstay/fork blade would be a simple way to mount a guard to give extra strength, i'm not keen on just using the disc tabs as mounting points.

While we're at it, i know the rules thread is over there >> but i think it should be compulsory to have rotors covered, they could do some serious damage.

On the subject of zip ties, my chainring and bashguard we're held on with zip ties, and we all know how much strain chainring bolts take eh ben? ;)

They are not chainring bolts ;)

On the subject of zip ties, my chainring and bashguard we're held on with zip ties, and we all know how much strain chainring bolts take eh ben? ;)