Ex to sumo conversion

Jon

Active member
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42
Location
ColoRADo
#1
Hey everyone,

Just finished up a somewhat painful supermoto conversion, and thought ya'll might like a peak!

The pain was really self induced. I bought some left over SM wheels from liquid performance, and wouldn't you know: they had a great deal on the SM front brake assembly! That thing fits right up to the larger disk, so it should make things easier, right?

alta before.png

Not so much. Turns out there are not a ton of axial to radial brake adapters for sizes other than 320mm. Bummer. I figured I could just make an adapter and move on.

I did a little measuring and design work and whipped up a few 3d printed models to test fit. Turns out that making something that would fit, was machinable by a noob like me, and would have sufficient strength was kind of hard. Took a few days, but I came up with a reasonable design... but it needed to be 7071-T6 to make me comfortable from a strength perspective. The material took forever to get here from ebay, but I was finally off and running.

alta machine setup.png

Took way too long to hog out all the material, but I finally made it work! Pretty stoked to just be able to switch wheels and a brake and have a totally different bike! Would I do it again? Probably not. I would either stick with the stock brakes or just buy SM forks. Or just buy an SM. But I guess we all need hobbies, right?

IMG_20200429_145852.jpg
alta bracket.png
 

Philip

Administrator
Staff member
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2,948
Location
Ann Arbor, MI
#2
Congrats!!! I thought there would be a ton of these Brembo radial caliper adapters already available for the KTM, but I was wrong! After spending a half a day goodling, I found something in Italy that might fit, or might not. At that point I sort of gave up. Congrats for pulling this off!
 

snydes

Moderator
Staff member
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2,006
Location
Pennsylvania
#3
Interesting you should post this, I was recently considering doing the same thing. It was once mentioned in a past post that an aftermarket KTM bracket would work for this purpose, but it sounds like this is not be the case? Perhaps Jon you could blueprint your bracket? I would be surprised if there were not several more members here that would be interested in an SM conversion for their bikes as well.

Nice work!
 

Jon

Active member
Likes
42
Location
ColoRADo
#4
I'd be happy to post my CAD/drawing for the part, @snydes . Just got a little lazy as I did the Solidworks on my work computer which is all the way upstairs ha! I'll add some detail about the design process and FEA that I ran.

I wish I would have taken more pictures while I was machining... oh well.

Next stop: dash protection bracket!
 

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