super slim
Zen MBB Master
Cruzbike Disk Brake set up
IS adapter to use on a Cruzbike with disc braked wheels.
https://www.npmjs.com/package/makerjs-disc-brake-mount-is
Front DF IS brake mount 87 mm from axle to furthest bolt, 49 mm to the closest bolt = 38 mm difference
Rear DF IS brake mount 78 mm from axle to furthest bolt, 40 mm to the closest bolt = 38 mm difference
On a DF bike the front Disk brake mount is 11 mm higher AND at a different angle, so that the same IS brake adapter can be used on a Rear 140 mm disk OR a front 160 mm disk, and are marked F160/R140, OR 0 mm IS.
AF180/R160, OR 20 mm IS, would be used on a DF 180 mm Front disk, OR a 160 mm rear disc.
On my Quest, the front AND rear welded disk bracket location are the SAME, at 76 mm distance from the axle to the furthest bolt, and 36 mm to the closest bolt = 40 mm difference, so different to the DF IS standards, but close to the Rear IS standard.
This could be why a F185 IS adapter (instead of the expected F180/R160) is required for a 160 mm Cruzbike front disk, and a F160/R140 (0 mm IS) adapter for the 140 mm Rear disk.
A F203 IS adapter is required for a Cruzbike 185 mm front disk.
Differences between a BB7 and TRP Spyre, HY-RD brakes
BB5 and BB7 have two 5.2 mm high spherical washers sets per bolt to allow the brake body to be centred to the disk, and this is built into its height design, so all of the brake pads are swept by the disc.
BB5 and BB7 have a alignment centering ball on the moving pad, but none on the fixed pad.
The BB7 has a pivoting ball support for the alignment of the moving brake pad off vertical, which is why they are much wider than the TRP Spyre, but it is needed as the disk is flexed inwards at a slight angle off vertical, to meet the fixed inner brake pad (That has no angular aligning ball) , as the outer pad applies force to the disk!
So BB7 brakes are VERY Tolerant of the welded bracket misalignment, but the penalty is extra weight and width, and only having one moving pad,
so a lot more readjustments are required to keep the brake pads wear even!
TRP Spyre and HY-RD have NO 5.2 mm high spherical washers sets per bolt to allow the brake caliper body to be centred to the disk, and rely on the welded disk brackets to be perfectly vertical, for good brake pad contact to the disk.
TRP Spyre and HY-RD, height of pad to Disc design, assumes the caliper is bolted directly to the IS adapter!
TRP Spyre and HY-RD have no aligning balls for the pads, as both pads move and the disk is not deflected.
TRP Spyre and HY-RD rely on the welded disk brackets to be perfectly vertical, for good brake pad contact to the disk. Once set up, then very few adjustments required as the disk is not bent to operate.
Set up videos
Avid BB7 setup, align calipers
stop disk brake squealling
Set up tips for TRP
TRP Clicking or shuddering fix https://www.youtube.com/watch?v=1T2RLgQoyvs
Fixing TRP problems with an off vertical, welded disk bracket
1 Adding 2 sets of spherical washers per bolts, to align the caliper body, like Avid disk brakes.
To add two sets of 5.2 mm spherical alignment washers, 3.0 mm to 5.2 mm needs to be filed or machined off the F185 IS adapter, to maintain the correct brake pad contact height with the disk.
This can not be done for the rear disc as there is not enough metal on the F160/R140 adapter to remove 2 mm, let alone 5.2 mm. (see photo to the right, with 3mm scribed lines)
The brake pads have JUST full contact with the disk, so no brake pad ridges are created that rubs on the outside of the disk!
On the Spyre this is when the radial clearance of the disk outer edge, to each end of the Spyre body disk slot is approximately 2.5 mm.
2 Filing the top of the IS adapter horizontal, to allow for non vertical welded bracket.
With the IS adapter, bolted to the frame, but the wheel and Caliper removed, then the frame is clamped to a bike stand, so the top surfaces of the IS adapter is horizontal, and the axle is Horizontal.
Then using a bubble level as a check, file the IS top surfaces horizontal,in BOTH directions, fit the brake caliper, with two spherical washers ABOVE the brake caliper, to allow for misalignment, and try a spare disk clamped to the caliper, using the brake cable adjustment, and check if the disk is vertical with a bubble level. If not try again!
IS adapters are cheap, Bike frames are NOT!!!
3 Filing the side of the welded disk bracket so vertical.
Remove the IS adapter and caliper, but leave the wheel and disk fitted, and mount on a bike stand so the axle is horizontal.
Using a good Idaho softwood block 25*12.5 * 50 long, bolted to the outside of the disk, so only a 0.1 to 0.5 mm gap to the Welded bracket!
Remove the wheel.
File the welded bracket, so there is an even gap to the block, and add shims between the disc and the wooden block, to deduce the gap, so it is easier to verify an even gap, and file the bracket again if required.
Sideways clearance between the IS adapter and the disc
http://www.dirtfreak.co.jp/cycle/sram/service/avid/avid_technical_specifications_my13_updates.pdf
http://my-sport.spb.ru/manual_1/2004 disc fit info.pdf
From page 5 of the Avid Tech manual, the wheel side of the front weld lug bracket should be 4 +-0.1 mm outside the fork inside edge.
From Page 11 of the Avid Tech manual, the disk flange should be 10.5 mm from the FRONT Non drive hub end.
From Page 2 of Avid Disk fit, the disk flange should be 10.16 mm from the FRONT hub end, and 15.27 mm from the REAR DRIVE hub end.
So the CRUZBIKE DRIVE FRONT welded lug should be 4 -(15.27-10.16) 5.1 = 1.1 mm inside edge past the fork inside edge, compared to a DF bike of 4 mm outside.
So the CRUZBIKE NON-DRIVE REAR welded lug should be 4 mm outside the fork inside edge (same as a DF Front!)
Measuring various IS adapters, for 140 to 203 mm disks, from different suppliers, the three thicknesses were 10.0 mm, 10.5 mm, and 11.0 mm, so no standard.
If the IS adapter is 10 mm thick, then the clearance to the the disc should be 2.4 mm
I checked my Quest V1.0 and it is 3.1 mm, with a 10.5 mm IS bracket giving me a 1.5 mm clearance with a 1.95 mm thick disk, and a 9.7 mm disk flange to hub edge, so ALL dimensions are different to the Standard!
Check the thickness of your IS adapter and buy a 10 mm thick new one if there are side clearance problems.
If this does not solve the problem, then file off 0.5 mm from the disc side of the IS adapter.
If this does not solve the problem, then add 1.0 mm washers to each side of the hub, to move each side of the forks out 1.0 mm
Sideways clearance between the 140 mm rear disc and the REAR seat stays on a Vendetta or a Silvio?
Check that the rear hub has a 100 mm spacing, and add 1.0 mm spacers to each side of the hub and aradite them in location, if not.
File off any stay protruding weld material if higher than the stays.
File off a maximum of 0.5 mm depth to a stay in this welded area, and create a gentle transition, and use fine emery paper to smooth out any file grooves in the filed area.
Add 1.0 mm spacers to each side of the hub and aradite them in location, to move both stays out 1.0 mm.
IS adapter to use on a Cruzbike with disc braked wheels.
https://www.npmjs.com/package/makerjs-disc-brake-mount-is
Front DF IS brake mount 87 mm from axle to furthest bolt, 49 mm to the closest bolt = 38 mm difference
Rear DF IS brake mount 78 mm from axle to furthest bolt, 40 mm to the closest bolt = 38 mm difference
On a DF bike the front Disk brake mount is 11 mm higher AND at a different angle, so that the same IS brake adapter can be used on a Rear 140 mm disk OR a front 160 mm disk, and are marked F160/R140, OR 0 mm IS.
AF180/R160, OR 20 mm IS, would be used on a DF 180 mm Front disk, OR a 160 mm rear disc.
On my Quest, the front AND rear welded disk bracket location are the SAME, at 76 mm distance from the axle to the furthest bolt, and 36 mm to the closest bolt = 40 mm difference, so different to the DF IS standards, but close to the Rear IS standard.
This could be why a F185 IS adapter (instead of the expected F180/R160) is required for a 160 mm Cruzbike front disk, and a F160/R140 (0 mm IS) adapter for the 140 mm Rear disk.
A F203 IS adapter is required for a Cruzbike 185 mm front disk.
Differences between a BB7 and TRP Spyre, HY-RD brakes
BB5 and BB7 have two 5.2 mm high spherical washers sets per bolt to allow the brake body to be centred to the disk, and this is built into its height design, so all of the brake pads are swept by the disc.
BB5 and BB7 have a alignment centering ball on the moving pad, but none on the fixed pad.
The BB7 has a pivoting ball support for the alignment of the moving brake pad off vertical, which is why they are much wider than the TRP Spyre, but it is needed as the disk is flexed inwards at a slight angle off vertical, to meet the fixed inner brake pad (That has no angular aligning ball) , as the outer pad applies force to the disk!
So BB7 brakes are VERY Tolerant of the welded bracket misalignment, but the penalty is extra weight and width, and only having one moving pad,
so a lot more readjustments are required to keep the brake pads wear even!
TRP Spyre and HY-RD have NO 5.2 mm high spherical washers sets per bolt to allow the brake caliper body to be centred to the disk, and rely on the welded disk brackets to be perfectly vertical, for good brake pad contact to the disk.
TRP Spyre and HY-RD, height of pad to Disc design, assumes the caliper is bolted directly to the IS adapter!
TRP Spyre and HY-RD have no aligning balls for the pads, as both pads move and the disk is not deflected.
TRP Spyre and HY-RD rely on the welded disk brackets to be perfectly vertical, for good brake pad contact to the disk. Once set up, then very few adjustments required as the disk is not bent to operate.
Set up videos
Avid BB7 setup, align calipers
Set up tips for TRP
Fixing TRP problems with an off vertical, welded disk bracket
1 Adding 2 sets of spherical washers per bolts, to align the caliper body, like Avid disk brakes.
To add two sets of 5.2 mm spherical alignment washers, 3.0 mm to 5.2 mm needs to be filed or machined off the F185 IS adapter, to maintain the correct brake pad contact height with the disk.
This can not be done for the rear disc as there is not enough metal on the F160/R140 adapter to remove 2 mm, let alone 5.2 mm. (see photo to the right, with 3mm scribed lines)
The brake pads have JUST full contact with the disk, so no brake pad ridges are created that rubs on the outside of the disk!
On the Spyre this is when the radial clearance of the disk outer edge, to each end of the Spyre body disk slot is approximately 2.5 mm.
2 Filing the top of the IS adapter horizontal, to allow for non vertical welded bracket.
With the IS adapter, bolted to the frame, but the wheel and Caliper removed, then the frame is clamped to a bike stand, so the top surfaces of the IS adapter is horizontal, and the axle is Horizontal.
Then using a bubble level as a check, file the IS top surfaces horizontal,in BOTH directions, fit the brake caliper, with two spherical washers ABOVE the brake caliper, to allow for misalignment, and try a spare disk clamped to the caliper, using the brake cable adjustment, and check if the disk is vertical with a bubble level. If not try again!
IS adapters are cheap, Bike frames are NOT!!!
3 Filing the side of the welded disk bracket so vertical.
Remove the IS adapter and caliper, but leave the wheel and disk fitted, and mount on a bike stand so the axle is horizontal.
Using a good Idaho softwood block 25*12.5 * 50 long, bolted to the outside of the disk, so only a 0.1 to 0.5 mm gap to the Welded bracket!
Remove the wheel.
File the welded bracket, so there is an even gap to the block, and add shims between the disc and the wooden block, to deduce the gap, so it is easier to verify an even gap, and file the bracket again if required.
Sideways clearance between the IS adapter and the disc
http://www.dirtfreak.co.jp/cycle/sram/service/avid/avid_technical_specifications_my13_updates.pdf
http://my-sport.spb.ru/manual_1/2004 disc fit info.pdf
From page 5 of the Avid Tech manual, the wheel side of the front weld lug bracket should be 4 +-0.1 mm outside the fork inside edge.
From Page 11 of the Avid Tech manual, the disk flange should be 10.5 mm from the FRONT Non drive hub end.
From Page 2 of Avid Disk fit, the disk flange should be 10.16 mm from the FRONT hub end, and 15.27 mm from the REAR DRIVE hub end.
So the CRUZBIKE DRIVE FRONT welded lug should be 4 -(15.27-10.16) 5.1 = 1.1 mm inside edge past the fork inside edge, compared to a DF bike of 4 mm outside.
So the CRUZBIKE NON-DRIVE REAR welded lug should be 4 mm outside the fork inside edge (same as a DF Front!)
Measuring various IS adapters, for 140 to 203 mm disks, from different suppliers, the three thicknesses were 10.0 mm, 10.5 mm, and 11.0 mm, so no standard.
If the IS adapter is 10 mm thick, then the clearance to the the disc should be 2.4 mm
I checked my Quest V1.0 and it is 3.1 mm, with a 10.5 mm IS bracket giving me a 1.5 mm clearance with a 1.95 mm thick disk, and a 9.7 mm disk flange to hub edge, so ALL dimensions are different to the Standard!
Check the thickness of your IS adapter and buy a 10 mm thick new one if there are side clearance problems.
If this does not solve the problem, then file off 0.5 mm from the disc side of the IS adapter.
If this does not solve the problem, then add 1.0 mm washers to each side of the hub, to move each side of the forks out 1.0 mm
Sideways clearance between the 140 mm rear disc and the REAR seat stays on a Vendetta or a Silvio?
Check that the rear hub has a 100 mm spacing, and add 1.0 mm spacers to each side of the hub and aradite them in location, if not.
File off any stay protruding weld material if higher than the stays.
File off a maximum of 0.5 mm depth to a stay in this welded area, and create a gentle transition, and use fine emery paper to smooth out any file grooves in the filed area.
Add 1.0 mm spacers to each side of the hub and aradite them in location, to move both stays out 1.0 mm.
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and will just choose the brake i like. If it takes some tinkering to fit, then so be it (of course, hopefully, no tinkering). 
skills than I.
