Advice about drilling headset

[sparklymarkly]

Hi all,
Sorry to be a pain again! I'm doing a dry-fit on my hydraulic brake as advised but need a bit of advice please.
The master cylinder has a 'stump' sticking out of it where the hose mounts. This will prevent the banjo from being tightened down at that point. This means I can either mount the banjo above or below the stump. I have test-fitted it and the photos show where the holes would need to be to carry the hose. I am concerned that one is possibly a bit too high & close to the edge of the headset. However, the lower one would mean the hole would be almost through the web/gusset inside the headset base which I don't like the idea of at all.
My question is basically, is the stump thing necessary? (I notice that both my motorbikes have the same thing on their m/cyls too).
If I grind it back a bit I could fit the banjo halfway betwen the two marks which I think would be a better place. It does look like it's already been filed as the end isn't painted black. Any thoughts please? Hopefully pics below to show what I mean (my 1st time!):
[url=http://www.lambretta-images.com/ar ... .jpg[/img][/url]
[url=http://www.lambretta-images.com/ar ... .jpg[/img][/url]
[url=http://www.lambretta-images.com/ar ... .jpg[/img][/url]
[url=http://www.lambretta-images.com/ar ... .jpg[/img][/url]

[soupy]

Hi all,
Sorry to be a pain again! I'm doing a dry-fit on my hydraulic brake as advised but need a bit of advice please.
The master cylinder has a 'stump' sticking out of it where the hose mounts. This will prevent the banjo from being tightened down at that point. This means I can either mount the banjo above or below the stump. I have test-fitted it and the photos show where the holes would need to be to carry the hose. I am concerned that one is possibly a bit too high & close to the edge of the headset. However, the lower one would mean the hole would be almost through the web/gusset inside the headset base which I don't like the idea of at all.
My question is basically, is the stump thing necessary? (I notice that both my motorbikes have the same thing on their m/cyls too).
If I grind it back a bit I could fit the banjo halfway betwen the two marks which I think would be a better place. It does look like it's already been filed as the end isn't painted black. Any thoughts please? Hopefully pics below to show what I mean (my 1st time!):
[url=http://www.lambretta-images.com/ar ... .jpg[/img][/url]
[url=http://www.lambretta-images.com/ar ... .jpg[/img][/url]
[url=http://www.lambretta-images.com/ar ... .jpg[/img][/url]
[url=http://www.lambretta-images.com/ar ... .jpg[/img][/url]

hi, i have the same set up and have found that it works better for me to have the hole between the to halfs of the head set for ease of taking apart the head set also the hose route is less restricted ,and i would file down that bump if its in your way ,you can also get different angles on the banjo unions to suit your needs. hope this helps

[rosscla]

Rather than take it through there can you turn it backwards and take it through the throttle support?

[shocky]

file a hole in the top put some clear silicone on there tops are easier to get than bottoms

[sparklymarkly]

Cheers Gents.
I see your points about running it through the top rather than the bottom (and notching rather than a hole) -good point.
Also as Shocky says, a top is easier to get (& to fit!!) if something changes. I think I'll tackle that job tomorrow night.
I'm sure routing it backwards & through the throttle support as Rosscla suggests would look great but might be a bit hard to do (for me anyway!).
Thanks for your help as always - much appreciated.

[Andy Pickering]

I notched mine also and it does make life easier re maintaince

Sent from my GT-I9000 using Tapatalk 2

[shocky]

heres one i did 2 yrs ago for someone

[dom]

If I was you mate I would drill a hole in the bottom half of the head set , I did a half and half job on mine but regretted it later because of the damage that was done to the cast lip of the top head set , it's much easier to repair a drilled hole rather than p155 about trying to re form a f@@ked up lip

[Devlam]

I need to do this in the very near future and I think I'll drill bottom part for that very reason. Can anyone tell me what diameter the hole needs to be? (I'm assuming hose is std dia?)

What's the thinking behind dry building the headset/master cylinder etc. assy?

I can understand dry building the bodywork with sheet metal moving and all that, but why the headset. I want to reduce any unforeseen problems

Chrs.

[joespeed]

your better drilling the top,gives a better route,and the bottom will become weaker and there is less of them about!