Pedals and
DISC BRAKES
Let me first start off by saying this was a pain in the ass. Even though I will be able to pedal for the first 10 feet of a hill and still have a disc break, I truly believe running a disc hub is the ideal way to go. So I'll jump right in... So we needed a flat or somewhat flat surface for the start of the disc mount. Each of the four nuts were welded to the bushing.
Next that bushing was welded at the four points (nuts) to the hub.
Then the disc needed a method of attachment to our mount, yet still enable me to change out the disc when needed. So with some washers to make for some added spacing the nuts were tightened and the studs ground smooth to give us a flat surface.
Weld another bushing to the nuts.
So with two flat surfaces now we mounted the disc to the bushing already welded to the hub. To ensure we had a true disc spinning in all directions we came up with the jig to hold a gauge that enabled us to shim the two plates to within .5mm.
Here the caliper mount has been spotted into place. Notice the fork ends that had to be ground wider to make room for the pedal.
Showing how little clearance you have from the spokes, the fork and the crank and caliper. To make the extra room needed on this side of the wheel we had to spread the forks and shim the pedal to adjust the side to side clearance to let the rotor spin.
The final mounted working unit