Issues with Monark fork

Captain Rainmaker

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I've hit a bit of a speed bump with my Monark fork.

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As you can see, even though I got the one with the disc brake option, there's pretty much no room between the fork and the hub for a brake rotor.

I don't know what the issue could be, but I have a sinking feeling that either I bought the wrong front hub or this fork has a flawed design. Anybody have any other ideas?
 

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Maybe it's the hub.

Maybe the sprocket hub is too thick.

Do you have a different hub/different model hub?
Not on hand, but I suspect you're right. Looking at pictures of other hubs, I can tell the one I picked is fairly thick in that dimension. I wonder if a center-lock hub would work instead.
 
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You could shave the button heads, after you tighten them in.

Or install thinner-head bolts.

All you need is 1mm clearance (.03937") or less.
 
I'm thinking change the button head bolt to a counter sink head bolt Grade #8
Of course this would require countersinking the Monark fork
 
You could shave the button heads, after you tighten them in.

Or install thinner-head bolts.

All you need is 1mm clearance (.03937") or less.
I'm thinking change the button head bolt to a counter sink head bolt Grade #8
Of course this would require countersinking the Monark fork

I pulled that bolt out and test-fit it again with the rotor on, just to see if that'd work...aaaaand it rubs on the fork tube.

I'm gonna take the fork and the wheel to my local bike shop that built the wheel and see what they have to say.

(Which reminds me: WORD OF ADVICE. If you're gonna drop the cash on a wheel build and already have the parts laying around, BEFORE YOU SPEND A CENT, MAKE SURE THEY FIT.)
 
Ooooh....so the rotor rubs on the fork tube?

How about a smaller rotor?

Test fit it, if you have one.

Any room for an axle spacer?

Of course, the LBS has tons more experience than what I have to offer.

If the hub absolutely has to be swapped,
I'd "machine" the sprocket hub, until the rotor fit.

Then if that doesn't work,
I'd find a sprocket hub with the same spoke-hole distance is exactly the same.....

then I'd re-spoke the wheel myself, using the same spokes.

After spending cash on the wheel build,
I'd be saying to myself over and over.....

I'm a motorized bike builder.....

it can't be THAT difficult!:)

Good luck.:)
 
Ooooh....so the rotor rubs on the fork tube?

How about a smaller rotor?

Test fit it, if you have one.

Any room for an axle spacer?

Of course, the LBS has tons more experience than what I have to offer.

If the hub absolutely has to be swapped,
I'd "machine" the sprocket hub, until the rotor fit.

Then if that doesn't work,
I'd find a sprocket hub with the same spoke-hole distance is exactly the same.....

then I'd re-spoke the wheel myself, using the same spokes.

After spending cash on the wheel build,
I'd be saying to myself over and over.....

I'm a motorized bike builder.....

it can't be THAT difficult!:)

Good luck.:)

Yeah, if I had a lathe, I'd chuck up the hub and shave a couple thou off the offending surface. Maybe it's a good thing I don't have one.
 
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