Rear Brake setup

This is probably going to be one of the greatest challenges with this project, setting up the rear brake system. I sourced a setup from a 2000 Yamaha R6 in good condition. The caliper pistons were close to being seized, the master cylinder and hoses etc are in good condition.

blow out

next step was to apply heat to the damaged areas with the aid of 2 butane/propane blow torches to soften them metal for the internal air pressure to push out the dented areas.

I got the first pipe fairly well sorted with a few of the deeper scores still visible, The second pipe was more of a challenge as the damage was greater . . . and I ran out of gas!

pumped

Next step was to plug both ends of each pipe after removing the baffles pressurized with air from a foot pump.

I used 5mm steel plate and an old bicycle tube as a seal with various brackets and clamps. I was able to get the pressure up to 80psi.

compressed expansions

A major concern for me was the whole topic of the expansion chambers, firstly sourcing a set and secondly fitting them with the non native frame present.
I managed to source a set from a forum member on RDnuts . they are a pair of early Microns under the name "Codnor Micron" with short can silencers. They have been  involved in a meeting with a foreign object at the diffuser point and need to be repaired.

Finished Article

Its been a while since I posted here so here are a few images showing the bike to date - Finished!