When mounting Honda VTR1000 front forks on a Honda VFR800 RC46 these parts can come in handy. 3D printed parts doesn't look sexy, but none of these parts are vissible, when mounted.
There are two sets of brackets for mounting of the front mudguard. The double LR set are for melt in place M6 brass inserts(Strongest solution) and with the two L+R brackets you have to cut threads in the brackets.
I recommend these Ruthex M6x12.7mm inserts:
https://www.amazon.de/dp/B09ZHBLGKM?
You can melt them in place using a standard soldering iron. But for nice results I reccomend using this Melting Aid Set:
https://www.amazon.de/-/en/ruthex-Soldering-Tips-Melting-Aid/dp/B0CDBSGSXY
Which can be used eg. with a Hakko FX-888D:
https://eleshop.eu/hakko-fx-888d-soldering-station.html
For ultimate control of melting aid, you can also consider to build this tool:
https://www.printables.com/model/553513-heat-set-insert-press
(There are many types, but this one is fairly simple)
Print the mudguard brackets with support.
Except for the Brakeline Rubber/DoubleRubber, print all parts in ASA for outdoor UV compatability. ABS might also work just fine since the parts are not really subjected to sunlight.
Although tempting; don't use PLA for any of this, it will creep under pressure and your parts will come loose... Also, PLA doesn't handle high temperature well and will probably warp on a hot summer day.
Mount the mudguard adaptors on the forks with M6x25 cylinder head screws and use threadlock.
There are various holders for brakelines. (The Trippeclamp holder has build-in support that must be removed after printing.)
You need two TrippleClamp holders, one for the left and one for the right brakeline.
You also need two FrontForkHolders.
You need four Brakeline Rubbers for the Trippclamps holders and the FrontForkHolders.
Brakeline Rubber/DoubleRubber should be printed in TPU95.
You need six 5mm width, good quality, cable ties. Two for each of the tripple clamp holders
and two for the DoubleRubber line part. I used Panduit PLT4.5S-C0 cable ties.
As of now, I have been using these parts, with the melted thread inserts, all summer of 2024 with out any issues :)
There are more than one option for the front calipers. You can find a lot of info on the subject on VFRworld:
https://vfrworld.com/forums/5th-generation-1998-2001.16/
I have chosen CBR954RR '03 front calipers and CBR600RR '03 Master.
To allign the brake calipers you need shims with a thickness of 3mm. Others have used two standard washers. But I'm using these 8.2x16x3mm stainless spacers:
https://www.ebay.com/itm/395114428563?var=663695806545
You will also need different caliper bolts, I have used Honda M8x32mm flange bolts [90107-MT3-003]:
https://www.cmsnl.com/products/bolt-flange-8x32_90107mt3003/
The standard CBR600RR Master has a style like the standard VFR, but the brake lever looks nothing like the VFR. Therefore I have replaced both levers with these that have the same styling:
Brake lever:
https://www.louis-moto.dk/da/saito-bremsegreb-langt-justerbart-sort-10017132?filter_article_number=10017177
Clutch lever:
https://www.louis-moto.dk/da/saito-koblingsgreb-langt-justerbart-sort-10017054?filter_article_number=10017068
I ordered custom brakelines at HEL:
https://auto.helperformance.com/hel-custom-stainless-steel-braided-brake-lines
With the following specifications:
Left Fitting
Banjo
Left Fitting Size
10mm Eye (M10, 3/8") - Most Common
Left Fitting Angle
20°
Right Fitting
Banjo
Right Fitting Size
10mm Eye (M10, 3/8") - Most Common
Right Fitting Angle
20° Side Bend
Stealth Heatshrink
Yes
Hose Colour
Black
Support One
Rubber Doughnut Grommet
Length
77cm
Line Purpose
Other
Left Fitting
Banjo
Left Fitting Size
10mm Eye (M10, 3/8") - Most Common
Left Fitting Angle
20°
Right Fitting
Banjo
Right Fitting Size
10mm Eye (M10, 3/8") - Most Common
Right Fitting Angle
Straight
Stealth Heatshrink
Yes
Hose Colour
Black
Support One
Rubber Grommet
Length
84cm
Line Purpose
Other
BrakelineHolderTrippleClamp.stl | 396.7KB | |
BrakeLineRubber.stl | 175.5KB | |
BrakeLineRubberDouble.stl | 280.4KB | |
FrontForkBrakelineHolder.stl | 652.4KB | |
FrontMudguardBracketL.stl | 373.7KB | |
FrontMudguardBracketLR.stl | 790.9KB | |
FrontMudguardBracketR.stl | 373.7KB |