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Message started by Sax Man on 05/16/10 at 20:51:08

Title: pillion mod
Post by Sax Man on 05/16/10 at 20:51:08

I've always disliked the big blocky looking pillion seat and thought it just looked out of place on the otherwise nice looking savage.
So I decided to replace it with a piece that would cover the diodes and wiring (since I really didn't want to move all that stuff) and
give a more finished look. Here is what I did:

1. Made a mock-up out of cardboard
http://www.dagooder.com/paul/pillion%20mod/01%20mock-up.jpg

2. Cut and shape 3 main parts from aluminum
http://www.dagooder.com/paul/pillion%20mod/02%20cut%20parts.jpg

3. Test fit
http://www.dagooder.com/paul/pillion%20mod/03%20test%20fit.jpg

4. Temporarily fasten 3 main parts with metal tabs and pop rivets
http://www.dagooder.com/paul/pillion%20mod/04%20temp%20fasteners.jpg

5. Temporarily fasten 2 mounting parts with pop rivets. The two support pins are temp fastened with small bolts from the other side.
Now we're ready for Alumaloy
http://www.dagooder.com/paul/pillion%20mod/05%20ready%20for%20Alumaloy.jpg

6. Alumaloy completed and all temp fasteners removed. The rubber bumpers on the support pins are doorstop bumpers
from hardware store. Now ready for foam and leather covering
http://www.dagooder.com/paul/pillion%20mod/06%20Alumaloy%20complete.jpg

7. Covering completed. I chose leather because I was able to stretch it (the piece was from the belly of the beast) without having
to sew - lining up seams can be a pain. It's bonded to the aluminum with lacquer based contact cement.
http://www.dagooder.com/paul/pillion%20mod/07%20cover%20complete.jpg

8. I originally thought the forward mounting tab would be sufficient support for the front of the cover but it wasn't as solid as I wanted.
And since it was too late to add 2 more support pins I came up with this solution - longer bolts, lock nuts, doorstop bumpers
http://www.dagooder.com/paul/pillion%20mod/08%20forward%20supports.jpg

9. before .... NOT!
http://www.dagooder.com/paul/pillion%20mod/09%20before.jpg

10. after....Yes!
http://www.dagooder.com/paul/pillion%20mod/10%20after.jpg

There were quite a few steps involved but I just used what I had on hand and went with it (no doubt truckinduc could have whittled
this thing out of a solid block of aluminum in about 30 minutes!)

Note that this is not a seat, just a cover. I personally think 2up on a motorcycle is way too dangerous - riding alone is bad enough.
Next time I remove the rear tire (perhaps for chain conversion) I will remove the rear foot pegs.

Title: Re: pillion mod
Post by JohnBoy on 05/16/10 at 21:31:01

I like it!!!
I think it looks cleaner and more to scale
I think I just might steal that idea!

Title: Re: pillion mod
Post by justin_o_guy2 on 05/17/10 at 02:59:25

I was expecting breast implants

Title: Re: pillion mod
Post by babyhog on 05/17/10 at 06:20:26

Awesome!

Title: Re: pillion mod
Post by dasch on 05/17/10 at 06:38:37

Clean and nice!!! Good job.

Title: Re: pillion mod
Post by Bigzuk on 05/17/10 at 07:45:34

That looks great !!!!
I feel the same way, I ride alone. I have been kicking around the same kind of thing made of alum. dia. plate to make a platform to put my bag on.
I never thought about leather, I like your design much better. I hope you don't mind if we copy it. After two back opperations I plan on adding a small backrest.

Thanks,
Bigzuk

Title: Re: pillion mod
Post by earlytimz on 05/17/10 at 11:21:16

Wow man, that's awesome!
It's amazing what can be accomplished with a little imagination and a willingness to give it a try... Bravo!

Title: Re: pillion mod
Post by kel30734 on 05/17/10 at 12:03:40

6F444A5758462D0 wrote:

Dimond Plate...... Good Idea Zuk. then I could relocate the Back rest and Have a Whol lot of room to Haul stuff.

Title: Re: pillion mod
Post by Sax Man on 05/17/10 at 19:24:36

Thank you all for the kind words.

Bigzuk, by all means copy, redesign, improve - that is why I posted it.

Title: Re: pillion mod
Post by Tanker2Biker on 05/18/10 at 10:40:58

456E607D726C070 wrote:

Let us see what the driver backrest looks like, where you get it (or how you make it), and how you mount it. I'm interested in the same thing. It'd be great if it were slide-in/slide-out, or maybe forward folding, so I could get my fat A55 over it :)

Title: Re: pillion mod
Post by buttgoat1 on 05/19/10 at 12:36:26

very nice
it definitely flows better than the stock pillion

Title: Re: pillion mod
Post by james may on 05/20/10 at 18:28:49

I like it.. Was thinking of how to go to a solo seat without chopping up the fender or going to a tiny little thing that looks like a spatula... was thinking of a way to make some kind of sheet metal cover or replacement for the rear seat and you seem to have done it.. I think it'd look good painted to match the bike..

Title: Re: pillion mod
Post by suzi-q on 05/20/10 at 18:57:08

;)great job. love it.

Title: Re: pillion mod
Post by LANCER on 05/22/10 at 07:51:05

NICE SLEEK LINES...VERY NICE WORK

Title: Re: pillion mod
Post by cursal on 05/27/10 at 19:29:41

Very nice indeed, changes the whole look of the bike.