K2 evo 900 disc brake modification with racesrc adapter

[Dr.Z]

This modification was completed with a disc brake adapter supplied by racesrc.  Purchased off of Ebay for 40 bucks, well worth the cost.   I was fitting Avid Elixir 3 hydraulic brakes to my K2 Evo 900.   The adapter worked great, but with this set up it needed additional machining in two areas to complete the installation.   The set up consisted of Mavic 717 rims with Shimano xt center lock hubs. Elixir 3 disc brakes with 160mm 6 bolt rotors.  Aligator rotor adapters and cable grips. The cable grips were used so the hydraulic lines didn't have to be dissembled.  The lower corner of the 5996 replacement adapter had to be machined  down a bit to provide proper clearance for the QD cam lock lever. This enabled the lever to be tucked neatly up into  the rear swing arm drop out. I also machined .125 Off the two mounting bosses of the disc brake adapter to provide for additional caliper alignment.  The avid calipers didn't have enough horizontal adjustment to align with the new rear rotor.  The machining of the bosses created a bit of a cradle for the 160mm rotor adapter strengthening the whole mounted assembly. Thanks to RACESRC for the time that was put into duplicating the no longer available 5996 adapter from K2.  The pics of the set up are below . Hope this helps anyone trying to fit disc to this type of frame.

Milled adapter bosses

Caliper Mounted on adapter. Milled recess provided additional caliper adjustment

Relief cut on lower corner of adapter to provide QD cam lock clearance

QD locked in up against Swing arm drop out

Rear disc assembly completed installation

Front disc assembly completed installation

[w2zero]

very clean install

[shovelon]

Very nice work.

[Thunderchild]

Very nice.  It might be better than the OEM adapter.

Thunderchild

[racesrc]

thank you for taking the time to show the photo's of the build. i didn't think of creating a clearance for the QR, i put the QR on the drive side. as with the machining needed for the horizontal adjustment of the caliper, my hayes lined up dead center so i had enough play to adjust in either direction about a millimeters worth. it's tough trying to design a part that will work in multiple applications without having the parts to measure and test those different applications. but excellent job. i wish the others that i sold a part to would show there photo's. it's kind of a cool thought that there are parts out there that came from my drawing paper. as for others who have chimed in on the subject, thank you for all your positive comments. i have this part on my bike and have yet to have any issues with it. and DR.Z i did find the actuall  FOX rear shock adapters at cambria bike on the web and my FOX RP23 works like a charm. right now im waiting for my new front 8" brake rotor and caliper adapter to arrive so i can try the 2003 marzocchi bomber dirt jumper 1 front fork i found in mint condition on ebay for $130 bucks. i sold my bomber mx comp on CL for a hundred and ten. new fork has a QR 20 front axle that is so perfect with my hope pro 2 hubset. the mx comp wont allow an 8" rotor, 6" max but the DJ1 allows 8". brakes will be even stronger. plus the 2 more inches of travel mate up even better to the almost 5" travel of the rear end. I LOVE THIS BIKE. my wife told me yesterday she baught me SHIMANO XT CRANK for x-mas, so next week i will post a couple of pictures of the bike, i think i will be pretty much done upgrading it for a while then.

DAVID

[racesrc]

DR.Z by the way CHAIN REACTION CYCLES in the UK has the marzocchi brake line mounts for your fork. like under 8 bucks with free shipping to the U.S. look under marzocchi fork parts. its a plug for the drive side and a hose guide for the brake side of your forks v-brake posts empty holes. try this link
http://www.chainreactioncycles.com/Models.aspx?ModelID=11730

[fyrstormer]

Looks great! Looks just like a modern bike.

[Old Proflexer]

nice looking build - well done

[Dr.Z]

thank you for taking the time to show the photo's of the build. i didn't think of creating a clearance for the QR, i put the QR on the drive side. as with the machining needed for the horizontal adjustment of the caliper, my hayes lined up dead center so i had enough play to adjust in either direction about a millimeters worth. it's tough trying to design a part that will work in multiple applications without having the parts to measure and test those different applications. but excellent job. i wish the others that i sold a part to would show there photo's. it's kind of a cool thought that there are parts out there that came from my drawing paper. as for others who have chimed in on the subject, thank you for all your positive comments. i have this part on my bike and have yet to have any issues with it. and DR.Z i did find the actuall  FOX rear shock adapters at cambria bike on the web and my FOX RP23 works like a charm. right now im waiting for my new front 8" brake rotor and caliper adapter to arrive so i can try the 2003 marzocchi bomber dirt jumper 1 front fork i found in mint condition on ebay for $130 bucks. i sold my bomber mx comp on CL for a hundred and ten. new fork has a QR 20 front axle that is so perfect with my hope pro 2 hubset. the mx comp wont allow an 8" rotor, 6" max but the DJ1 allows 8". brakes will be even stronger. plus the 2 more inches of travel mate up even better to the almost 5" travel of the rear end. I LOVE THIS BIKE. my wife told me yesterday she baught me SHIMANO XT CRANK for x-mas, so next week i will post a couple of pictures of the bike, i think i will be pretty much done upgrading it for a while then.

DAVID

Hey Dave
Shock Forks and the cranks sound like an awsome upgrade. Put a post up when your done.  The rear adapter works great. , I put about 150 miles on the set up so far with no problem. I don't ever anticipate any issues with this mount Extremely nice fit and very secure The bit of machining I had to do was anticipated since each build is different. That's great that you found some prefabbed shock mounts for the fox RP. I like to do things the hard way. Not really.  after you said you found some on Price Point I did some searching for rock shox mounts and found some by vivid. Exact size I could have used last year. I guess it's all part of the learning curve.  I posted a new pic of my next project.  I'll either start a new build if I can find the parts or increase my front frame to a large.

Thanks again Dan

[Dr.Z]

DR.Z by the way CHAIN REACTION CYCLES in the UK has the marzocchi brake line mounts for your fork. like under 8 bucks with free shipping to the U.S. look under marzocchi fork parts. its a plug for the drive side and a hose guide for the brake side of your forks v-brake posts empty holes. try this link
http://www.chainreactioncycles.com/Models.aspx?ModelID=11730

Thanks for the link.  Order a set with some new rubber for icy roads.

[racesrc]

thank you for taking the time to show the photo's of the build. i didn't think of creating a clearance for the QR, i put the QR on the drive side. as with the machining needed for the horizontal adjustment of the caliper, my hayes lined up dead center so i had enough play to adjust in either direction about a millimeters worth. it's tough trying to design a part that will work in multiple applications without having the parts to measure and test those different applications. but excellent job. i wish the others that i sold a part to would show there photo's. it's kind of a cool thought that there are parts out there that came from my drawing paper. as for others who have chimed in on the subject, thank you for all your positive comments. i have this part on my bike and have yet to have any issues with it. and DR.Z i did find the actuall  FOX rear shock adapters at cambria bike on the web and my FOX RP23 works like a charm. right now im waiting for my new front 8" brake rotor and caliper adapter to arrive so i can try the 2003 marzocchi bomber dirt jumper 1 front fork i found in mint condition on ebay for $130 bucks. i sold my bomber mx comp on CL for a hundred and ten. new fork has a QR 20 front axle that is so perfect with my hope pro 2 hubset. the mx comp wont allow an 8" rotor, 6" max but the DJ1 allows 8". brakes will be even stronger. plus the 2 more inches of travel mate up even better to the almost 5" travel of the rear end. I LOVE THIS BIKE. my wife told me yesterday she baught me SHIMANO XT CRANK for x-mas, so next week i will post a couple of pictures of the bike, i think i will be pretty much done upgrading it for a while then.

DAVID

Hey Dave
Shock Forks and the cranks sound like an awsome upgrade. Put a post up when your done.  The rear adapter works great. , I put about 150 miles on the set up so far with no problem. I don't ever anticipate any issues with this mount Extremely nice fit and very secure The bit of machining I had to do was anticipated since each build is different. That's great that you found some prefabbed shock mounts for the fox RP. I like to do things the hard way. Not really.  after you said you found some on Price Point I did some searching for rock shox mounts and found some by vivid. Exact size I could have used last year. I guess it's all part of the learning curve.  I posted a new pic of my next project.  I'll either start a new build if I can find the parts or increase my front frame to a large.

Thanks again Dan

i think my frame is a large, that frame looks like a "way big". you should measure the top tube center to center and the seat tube center to center so we can compare.
DAVID

[racesrc]

hey dan, i only say that because your head tube is longer than mine. i dont have my bike with me right now but i will take measurements of it tonight when i get home. ill be riding it tomarrow since my brake rotors are going to be here today. ive been waiting a week for them, (damn holiday shipping). i couldnt use the 6" rotor up front without a diferent adapter so i figured i would just go ahead and order the needed parts all at once to go 8". i tried to ride to work with just the rear brake but going down my hill was insane so ive been waiting.

DAVID

[racesrc]

so here's some stats, someone who knows these bikes might be able to tell me what size this thing is.

'99' EVO 1000.

SEAT TUBE ROUGHLY; 19.5"      FROM CENTER CRANK TO .5" BELOW TOP TUBE & SEAT TUBE JUNCTION

TOP TUBE                ; 22.50"    FROM CENTER HEAD TUBE TO CENTER SEAT TUBE FOLLOWING TOPTUBE   IN A STRAIGHT LINE WITH  SAME SLOPE TO INTERSECTION OF SEAT TUBE

HEAD TUBE              ; 4.875"

DAVID