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Tomorrow I’ll whip up some sort of comparison. Deflection can be analyzed by integrating across the width of the bar so if the outer 75% of a 35 mm bar were identical to a comparable 31.8 mm bar, the deflections would be identical over that length and the only difference would come down to that innermost 25%.

Correct they are thermosets, most are very, very stiff in compressive loading situations, >30ksi. Just as stiff as the aluminum caliper under similar compressive loadings. The only reason there would be impressions and deformations in the phenolic piston blocks is due to poor design leading to stress raisers that allow for point loading putting the material into a plastic deformation condition above typical elastic conditions. I personally have never seen such issues with the phenolic inserts in my Hopes, and I have yet to ever hear of anyone mention it before. I don't have a stress-strain curve for Bakelite or...

Also feel like a hard shell over armor could slide along terrain better and not grip the ground and throw you around as much. Avoid all the snagging fabric.

You can get the correct DOT fluid in any automotive shop. For any DOT compatible brake. Good luck with that with mineral oil brakes. You have different oils WITHIN the same manufacturer (Shimano), let alone between manufacturers. I know I'm beating a dead horse at this point and derailling the thread at the same time, but sorry, I see ZERO benefits from using mineral oil vs. DOT fluid in brakes... If anything, also reading people's experiences about it, it's more complicated than anything, cleaning it up is a pain compared to DOT and the aforementioned issue of finding the correct...

If we're talking about wishes and brakes... I wish this mineral oil craze would stop.

There is no reason to make a cast "mockup" that doesn't have all the features just to check dimensions. Every detail on the tooling can affect dimensions so you want to have the tool as final as possible and then make corrections. Adding bracing later will affect the bridge and by proxy possibly the lower to twist differently, will require different material amount to fill the void, etc., essentially making a new part. The two holes being breather holes, possibly but they are in a weird place to be able to reach them. I'd kinda think they might be there...

While a more massive object requires proportionally more force to achieve a specific acceleration, it’s important to remember that in compression the thing imparting this force on the unsprung mass is extremely massive. The unsprung mass is going to get out of the way of whatever impact it encounters. Rebound is really the question.

Yeah reserves have been coming with 20mm 1/1s for a few years now

why do you think everyone should have the same length rear center but a size specific front center and do you believe every size rides exactly the same?