Fixed XT V-brake lever bushing with Jockey wheel spacer :D

[Twisty]

I did one of my better bodge fixes last week so thought it would be good to share it.

I've had some of the original 1996/1999 XT - V brake levers lying around unused for years because the top bushing had disintegrated. I was keen to fix them because I really, really like the levers but was struggling to find replacement parts. Until last week when I was installing some BBB jockey wheels and the thought occurred that the spare plastic shims that come with them might be the perfect fit for the levers.

The ID of the 'C' spacers are a good fit on the metal pin of the levers but I needed to spend 5 mins whittling down the OD with a sharp knife to allow them to be pressed into the lever body, the 'step' on the base also needed to be trimmed off. It looks ugly I know but it doesn't matter that the OD is not smooth as only the ID is a moving bearing surface.

Gave everything a good clean, used a bit of dry chain lube on the bearing surfaces, bit of blue loctite on the threads and reassembled. It probably wasn't a good idea to test them out for the first time in a race but fortunately they worked faultlessly.

Links to full size images
http://i.imgur.com/TVVVmtY.jpg
http://i.imgur.com/ZjE4Q5m.jpg

 

[02gf74]

A fix is a fix , but will plastic last?

What is the id and od? You can get brass tube. Aluminium and steel, brass would be best as its self lubricating.

 

[Twisty]

Re:

Sorry, ID is internal diameter and OD is outside diameter.
The original bushings are plastic and lasted a few years of regular riding, and i hope the replacements last just as long, maybe slightly longer as they are a little chunkier than the originals. I've worn through 2 top bushings (both on front brakes), strangely even though the bottom bushings are also plastic, those are not showing any significant signs of wear.
As you can see from the after shot, once assembed it looks exactly as original.

Brass could be good, but a tube wouldnt work as it would need the collar to stop it falling off the lever, smooth plastic on smooth steel is also self lubing but I thought adding a little teflon lube wouldnt do any harm

 

[02gf74]

I know what id od is, was asking size preferably in mm.

Ok, my suggestion would not be as easy due to top hat shape and since original were plastic, your solution is as good. :idea:

Happy braking !

 

[Twisty]

Oops, sorry I misunderstood.
I didn't get my vernier calipers out for this one so I don't know measurements. I had all the bits conveniently in front of me so I just tested out at what bits fitted well together and started trimming until it was a good fit.