Disc brake conversion


I decided early on that I wanted disc brakes on this bike. They'll provide the necessary stopping power for the 2000 watts of power that I expect this thing to put out, and hopefully look a bit bogan. Unfortunately the Dyno frame doesn't have mounts for the disc brake callipers. This wasn't a problem for the front wheel, as it's easy enough to fit new forks. However, for the rear wheel something more involved was necessary.

I'd seen this guy from California who runs a shop called Wolf Creative Customs make his own rear dropout attachments. Basically he'd machined extensions for his rear dropout, and drilled out disc brake mounts. This extends the wheel base, and adds more space for batteries behind the seat post.

My friend Jeremy very kindly offered to help with designing and fabricating the dropouts. We took the bike into his work and started playing around with ideas. We got inspiration from the dropouts made by Paragon Machineworks, and also managed to find the "ISO" dimensions for the disc brake mounts. Jeremy's work has access to all sorts of fancy equipment, which made the whole design process really fluid.

Tracing the frame
Importing the trace into Solidworks
Prototype shapes were laser cut out of acrylic, fitted, and adjusted until we arrived at a geometry we were happy with. We tried about 3 or 4 shapes until we were satisfied. It was really efficient being able to make a small adjustment on the CAD software, and then having a freshly cut prototype 5 minutes later. Much more sophisticated than the old mate Stu cardboard cutout method which I usually employ.

Lasercutting prototypes

First cut
Jeremy's work has these incredibly impressive CNC machines. One was programmed with the design files, tools, and other settings, and then set to cut. It was pretty awesome to watch. Once the parts were machined, they were fitted, and then touched up with a "manual" mill. They came out awesome, and will be anodised at a later date.

Machining the final parts

Machined parts, fresh from the billet
Touching up the insets on the manual mill

The bike was then passed onto Tim White, who re-laced the wheel onto a new hub with rotor mounts. I think it looks pretty sweet!

All fitted together - look at all that space for batteries behind the seat!

Brake side dropout

Drive side dropout

Top-down view

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