Spent most of this weekend working on the rear brake linkage. For starters I knew I needed a con-rod longer than the original, so I ordered some 5mm bar and cannibalized the stock one.
Didn't think it through though, as the stock rod is tapped M6 at the end, but a 5mm bar isn't thick enough to achieve the properly, so it just got a slight thread on it. I welded it to the stock connector and also welded a washer on. It will do for now, I've ordered some 6mm bar and M6 studding to make a better one.
Next problem. The new hardtack frame means that the brake lever on the rear drum sticks too far out so the conrod clashes with the frame
To rectify this I carefully made two slits in the lever, not quite all the way through, and bent it to the right angle
Now I thought I had got everything in place apart from the spring, but after lots of fiddling I still couldn't get the adjustment right for the foot pedal. What I didn't realise until I looked back at the stock frame was that there was additional adjustment in the form of a screw which acts as a back stop.
So after a seriously thick coat of thinking I decided that I needed this and that the simplest way to do it was to mimic the stock frame with a screw of my own. I started by just drilling and tapping my frame in the right place.
I wasn't satisfied that this was secure enough, and I needed another connection for the spring, so I went with the threaded bung idea again and made two mini M6 bungs.
Tacked them into the frame;
And that did the trick!
You can see i also had to lengthen the step in the lever for the bolt head to sit nice and flat. I tested it out and I can now adjust things up so the rear brake feels nice and sharp. Just need to remake the con-rod when the bits get here.
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