Busa brake caliper on a Virago

We created a template for the new adapter plate on the backside of a PBR carton of course.

We used one clamp to keep the wheel from spinning and another clamp that held the caliper exactly where we wanted it.

Chris cut off the bottom mounting hole and repositioned it in the new location against the caliper.

Chris made the adapter plate from 3/16 steel and we test fitted it.

Again we used some pieces of the PBR carton to space the pads out for mock up.  Is there anything you can't do with a PBR carton?!

Chris beveled all the edges and cleaned everything up in order to weld.

It took a couple tries to get the TIG to weld the cast aluminum correctly.  We preheated the part in the oven at 350 for about 20 minutes.  Once we preheated it the TIG could maintain a good puddle and the weld was successful.

Here is a picture of the inside pass,  we unbolted the adapter plate that was holding everything in place and welded up the other side and the ends.

Chris contoured the adapter to flow better with the caliper and we powder coated everything faux chrome.  It goes well with the polished aluminum lowers.  Now Chris has a 6 piston caliper on the front end of the Virago.  He also went from a dual disc setup to a single in order to open up the right side and not hide the wheel.