So the question - has anyone ever tweaked the brake bridge on an aluminum bike, for whatever reason, and had it live? I know that it's theoretically not a great idea to yield aluminum and rely on its strength afterwards. But if I could move it up 1-2 mm, it would make a big difference in its ability to handle road debris.
Is there material on the bottom that doesn't look too structural and can be removed?
You could try shorter tires. Tires of the same nominal size vary quite a bit.
Cielo by Chris King Cross Racer
Rewelding the bridge is a possibility, but I'd rather not repaint the frame as it's 7 years old.
If I bend and it's not quite centered, that can be compensated for at the brake caliper. But I'm not leaning that way at the moment, unless I hear from a builder that it can be slightly bent without issue.
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I know a friend who filed down the underside of his brake caliper just a little to get more clearance. Would that be possible or even safe (along the lines of drillium)?
You can use an offset caliper mounting bolt.
Or file the bridge mounting hole a little so you can slide the mounting bolt up.
Or get a different caliper that has more clearance.
Or take a file to the caliper you have.
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