| Next job on the list; a few years ago I
made a sandcast clutch pedal and was planning to make a matching
brakepedal since then. So here we go! I had a midcontrol on the
brakeside before, but with the IDF carb there is plenty of legroom
so I am changing back to forward control.
| I started by making a quick and dirty mockup
in steel to get the mechanics figured out, then laserscanned that
and started designing in CAD. Once I was happy with the design
I 3d printed the 4 pieces of a positive mold, and used the printed
parts to do the sandcasting. If you want to try this don't forget
that the mold needs to be about 2% oversize as the aluminium will
shrink when cooling.
| After casting the parts were cleaned up
and machined, the trickiest part is to fixture these rather organically
shaped parts under the milling machine, but with some imagination
that can be done. The brake reservoir will remain under the swingarm
so this system will use a rather long puchrod to transfer the
movement of the pedal to the reservoir, more about that next time...