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Re:

Hi, I'm looking at doing a similar thing (I must be crazy! :facepalm: ) in order to fit an old Hope mechanical disc caliper to the rear of my frame. It doesn't use any "normal" standard, so custom is the way to go, or get fittings brazed onto the frame.
But I'd like to try the adapter route first to see how it goes.

Is the grade of aluminium particularly important? I see on eBay you can get ally plate in various thicknesses but it's just listed as "Aluminium", would this be ok?
Where did you get your ally plate from?
 
Raw aluminium is pretty weak so you want an alloy. There are many different types.

I used 6082 t6 which is easy to work with and described as medium strength, and reasonable cost.

I bought a short length of 10 mm plate (which is same thickness of adapters and lugs on frames and forks) from ebay, seller bradleyi5.

There aew many sellers and different grades available, avoid raw aluminium.

Make sure you get the holes dine first and then concentrate on the shaping, if they are not in the right place, you will have list a lot of effert as its the shaping that takes time.
 
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