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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Finally chopped /cgi-bin/YaBB.pl?num=1333138513 Message started by mcentric on 03/30/12 at 13:15:12 |
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Title: Finally chopped Post by mcentric on 03/30/12 at 13:15:12 I was hoping to get this project started before Christmas, but being the master procrastinator that I am I'm now starting my bobber project right at the start of the riding season ::) At least looking out at the beautiful riding weather from the workshop is a great motivator to get my butt in gear. I'm not doing anything too drastic this time around: *new rear fender and struts. Fender made from harley front fender. *cutting original fender struts *side mounted licence plate and tail light *'frisco style gass tank modified with external gass level gauge *fake oil tank for housing battery and electrics Hoping to have this done by next Wednesday :-? These pics represent where I got today A quick mock-up http://p1.bikepics.com/2012/03/31/bikepics-2375298-full.jpg The donor Harley front fender http://p1.bikepics.com/2012/03/31/bikepics-2375299-full.jpg Splitting, widening, and welding http://p1.bikepics.com/2012/03/31/bikepics-2375300-full.jpg http://p1.bikepics.com/2012/03/31/bikepics-2375301-full.jpg http://p1.bikepics.com/2012/03/31/bikepics-2375302-full.jpg Mounting bracket for rear fender http://p1.bikepics.com/2012/03/31/bikepics-2375303-full.jpg Result of day 1 http://p1.bikepics.com/2012/03/31/bikepics-2375304-full.jpg http://p1.bikepics.com/2012/03/31/bikepics-2375305-full.jpg (hopefully the pics should be working now) Mike |
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Title: Re: Finally chopped Post by Smokestack on 03/31/12 at 04:56:39 Pics not workin'? |
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Title: Re: Finally chopped Post by mcentric on 03/31/12 at 05:42:11 Are they not showing up? strange... I can see them here. Might be my Dropbox acting up. I'll try attaching them directly Mike |
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Title: Re: Finally chopped Post by Bobbert on 03/31/12 at 11:13:10 Nice work. What are you doing for fender struts? |
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Title: Re: Finally chopped Post by mcentric on 03/31/12 at 14:20:17 033E333423253E3C3E34510 wrote:
Thanks :) I'm not a 100% sure yet actually. I'm leaning towards some sort of twisted steel bar thing, but I'll be trying some stuff out on Monday. I put in a couple hours today and got a little further on the rear fender. Finished welding and added a gusset to the bracket http://p1.bikepics.com/2012/03/31/bikepics-2375592-full.jpg Welds ground down http://p1.bikepics.com/2012/03/31/bikepics-2375593-full.jpg Sandblasted http://p1.bikepics.com/2012/03/31/bikepics-2375594-full.jpg I put a coat of primer on it after the sandblasting but forgot to take a pic. Mike |
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Title: Re: Finally chopped Post by DNLMusik on 04/02/12 at 01:02:56 Looking really good! I like your taste 8-) |
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Title: Re: Finally chopped Post by justin_o_guy2 on 04/02/12 at 03:07:22 4A4042437B7D67650E0 wrote:
You gonna lick him Again? |
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Title: Re: Finally chopped Post by mcentric on 04/02/12 at 12:53:09 757F7D7C4442585A310 wrote:
Thanks :) just hope I don't ruin the lines with the seat... :-/ |
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Title: Re: Finally chopped Post by mcentric on 04/02/12 at 12:55:12 Time is racing away from me... I only got in 3.5 hours today and all I got done in that time were the fender struts. Some of the welds still need grinding, and then I need to make a decision on what kind of finish to put on them. I'm not too pleased with the left side strut, and how the bend over the belt turned out, but I'm not going to do anything with it now. http://p1.bikepics.com/2012/04/02/bikepics-2377114-full.jpg http://p1.bikepics.com/2012/04/02/bikepics-2377115-full.jpg http://p1.bikepics.com/2012/04/02/bikepics-2377116-full.jpg Mike |
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Title: Re: Finally chopped Post by justin_o_guy2 on 04/02/12 at 13:18:25 You got them to come out to the same height & land at the mount point on both sides, you got the twist the same, from front of the support, wires reach out & back as they rise,,Looks good to me, IDK what kinda "feel" youre goin for, but undercoat mite make a decent finish for them, depending on what you want. |
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Title: Re: Finally chopped Post by mcentric on 04/02/12 at 14:11:47 5F4046415C5B6A5A6A52404C07350 wrote:
Thanks. The fenders and tank are gonna be flat black, so I might go for the same hot rod red that are going on the rims. Mike |
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Title: Re: Finally chopped Post by skeebo on 04/02/12 at 15:03:31 Two thumbs up on the fender split, that was gutsy. Tons of work man keep it up! |
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Title: Re: Finally chopped Post by justin_o_guy2 on 04/02/12 at 23:33:01 Ya know, you can get colored rubber. IDK how the colors would match, but Harbor Freight carries red "handle dip",, If you could get an even coat, it would look pretty good,, I still think Undercoating from a spray can would look good,, but waddooo I know? Heck,, I think they look good enough to chrome,, |
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Title: Re: Finally chopped Post by mcentric on 04/03/12 at 11:22:34 3B242225383F0E3E0E36242863510 wrote:
Chrome actually crossed my mind today, but I promised myself there wouldn't be any chrome at all on this bike :) Mike |
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Title: Re: Finally chopped Post by mcentric on 04/03/12 at 11:42:56 I was sure my students would all be off for Easter holiday today so I would have the workshop to myself, but I was very wrong. So half the day went to project meetings :( But, at least I got the seat done.... almost I made a cardboard template to get the shape I wanted http://p1.bikepics.com/2012/04/03/bikepics-2377430-full.jpg Then I shaped the seat from 2mm aluminum sheet http://p1.bikepics.com/2012/04/03/bikepics-2377431-full.jpg I made a support "skeleton" from steel http://p1.bikepics.com/2012/04/03/bikepics-2377432-full.jpg The seat hinge is made from steel with a brass center as a bearing http://p1.bikepics.com/2012/04/03/bikepics-2377434-full.jpg Test fitting the seat on the support structure. The seat will be pop riveted to the support. Short seat springs will be placed between the support structure and frame http://p1.bikepics.com/2012/04/03/bikepics-2377435-full.jpg http://p1.bikepics.com/2012/04/03/bikepics-2377436-full.jpg Mike |
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Title: Re: Finally chopped Post by DNLMusik on 04/04/12 at 01:20:45 I love your work. You seem to have some skills with aluminium and steel! |
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Title: Re: Finally chopped Post by mcentric on 04/04/12 at 02:10:09 707A787941475D5F340 wrote:
Thanks :) having access to a well equipped workshop certainly helps. Mike |
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Title: Re: Finally chopped Post by DNLMusik on 04/04/12 at 09:49:58 654143494D44280 wrote:
Thanks :) having access to a well equipped workshop certainly helps. Mike[/quote] Makes a huge difference. I'm renovating my house right now and building a workshop with all the tools I could ever need for a proper bike project. It should be up and running within 2 months, then I'll start with the savage! |
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Title: Re: Finally chopped Post by mcentric on 04/05/12 at 07:36:20 So, I got a little further today. * I added a some steel to mount the seat springs on and to close up where I cut the frame. * Finished mounting the seat. I added some springs from a bicycle seat. I'm not going to go as far as to say that it was comfortable, but it was actually better than I had feared. * Side-mounted the license plate and the new tail/brake light. * Mocked up the fake oil tank. Still needs to be welded and make a battery box in the center. I'm a little unsure if I made the tank a bit big... The left side of the tank will hold the electronics, and the right will be for tools, registration papers , etc. I borrowed one of my students to model the savage :) (it should be said that I am both taller and... uhm... wider than him) http://p1.bikepics.com/2012/04/05/bikepics-2378213-full.jpg Various shots of the bike as it stands now http://p1.bikepics.com/2012/04/05/bikepics-2378214-full.jpg http://p1.bikepics.com/2012/04/05/bikepics-2378215-full.jpg http://p1.bikepics.com/2012/04/05/bikepics-2378216-full.jpg http://p1.bikepics.com/2012/04/05/bikepics-2378218-full.jpg I won't get to do any more on the bike until monday. Mike |
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Title: Re: Finally chopped Post by dasch on 04/05/12 at 08:03:51 Really nice!! Yup, well equipped shop helps! ;) |
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Title: Re: Finally chopped Post by justin_o_guy2 on 04/05/12 at 08:10:36 Is there enough room under that fake oil tank to let the belt move up when the suspension is compressed? |
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Title: Re: Finally chopped Post by mcentric on 04/05/12 at 08:30:45 6A6F7D6D660E0 wrote:
Thanks! It sure does, and I'm lucky enough to have this shop at my disposal every day :) http://youtu.be/-XB-7lHAT8c?hd=1 The sheet metal tools and the CNC shop are not in the video. Mike |
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Title: Re: Finally chopped Post by mcentric on 04/05/12 at 08:33:45 637C7A7D60675666566E7C703B090 wrote:
Well spotted ;) Not as it stands now, no. But it'll be mounted all the way up under the backbone which should give it clearance enough. If not, the tank will be notched. Mike |
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Title: Re: Finally chopped Post by mcentric on 04/09/12 at 05:54:57 I decided not to go with aluminum for the fake oil tank... or actually, running out of argon made the decision for me :) Things are taking a lot longer than I hoped,and now that the Easter holidays are over work on the bike will be a bit more sporadic. I think I finally found a version of the battery box/electrical housing that will work. http://p1.bikepics.com/2012/04/09/bikepics-2380914-full.jpg http://p1.bikepics.com/2012/04/09/bikepics-2380915-full.jpg http://p1.bikepics.com/2012/04/09/bikepics-2380916-full.jpg All this work sort of feels a little futile when I, once again, have to admit the fact that a Suzuki Savage will always be too small for a big fat guy :-? http://p1.bikepics.com/2012/04/09/bikepics-2380917-full.jpg http://p1.bikepics.com/2012/04/09/bikepics-2380918-full.jpg Mike |
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Title: Re: Finally chopped Post by EJID on 04/09/12 at 07:49:03 092D2F252128440 wrote:
Progress on the bike looks great! But if you are concerned about being cramped, you might want to consider some forward controls... It's amazing what a different feel it gives the bike by moving your feel out there 4"-6" I'm not a big guy my any means (5'9" with a short 30" inseam) but I put on a set of 4" extensions and I feel much more comfortable now 8-) |
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Title: Re: Finally chopped Post by mcentric on 04/09/12 at 08:00:24 Thanks :) Forward controls are absolutely on my "to do" list. I had a sliver of a hope that when I moved the seat back it would be a bit better. But with the seat now considerably lower it actually feels even more cramped. I'll be CNC'ing som out of 6061 alu. as soon as I finish the current list :) |
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Title: Re: Finally chopped Post by skeebo on 04/09/12 at 09:05:58 Nice work on the battery box....Looks like you built it around the stock battery. http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/425309_255837057838038_228669960554748_558564_125544080_n.jpg |
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Title: Re: Finally chopped Post by mcentric on 04/09/12 at 09:51:09 5D454B4B4C412E0 wrote:
Thanks. Well, not the stock battery, but judging from how it fit in the original battery box I'm assuming it's pretty close in size. It hadn't really occurred to me to get a smaller battery... doh! :-[ As I don't have indicators, and only an LED taillight in addition to the headlight I guess I could have gone for something a lot less than the 14Ah stock battery. Oh well, the bike's a work in progress :) Mike |
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Title: Re: Finally chopped Post by skeebo on 04/09/12 at 10:50:15 Ya....If you go to a smaller battery then you have room tool kit... ;) |
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Title: Re: Finally chopped Post by mcentric on 04/13/12 at 03:40:54 Slooooooowly getting there. Upper and lower tank mount finished. Still need to dress the welds on the lower mount. Rubber discs between mounts and tank should hopefully dampen some vibration to the tank. http://p1.bikepics.com/2012/04/13/bikepics-2382919-full.jpg http://p1.bikepics.com/2012/04/13/bikepics-2382920-full.jpg Fake oil tank bondo'ed, primered and mounted. It looks like the left side will just clear the belt when suspension is bottomed out... hopefully :) also put is some rubber dampeners between tank and frame. http://p1.bikepics.com/2012/04/13/bikepics-2382921-full.jpg And now the fun begins >:( Re-wiring most of the harness. Shortening most wires to fit in the new compartment, and removing stuff I'm not using. http://p1.bikepics.com/2012/04/13/bikepics-2382922-full.jpg Mike |
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Title: Re: Finally chopped Post by mcentric on 04/19/12 at 12:36:19 Things are very hectic at work with exams coming up, so progress has been slow. I've started cleaning up the harness. The previous owner had wrapped the whole thing with electrical tape and now it's a darn sticky mess. Acetone to the rescue!(The bottle is isopropyl that didn't work on the tape residue) http://p1.bikepics.com/2012/04/19/bikepics-2386737-full.jpg I'm gonna have the old school external-clear-hose-gass-gauge dealy on the tank. I wanted the fittings to be brass, as I really like the way brass looks against flat black. So, I've gotten a little work done in my home workshop: Threaded steel bungs to weld to the tank 90deg. brass fittings to fit 9mm ID hose. http://p1.bikepics.com/2012/04/19/bikepics-2386742-full.jpg http://p1.bikepics.com/2012/04/19/bikepics-2386746-full.jpg Mike |
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Title: Re: Finally chopped Post by LANCER on 04/19/12 at 17:10:52 Very nice work...wish I had similar skills |
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Title: Re: Finally chopped Post by mcentric on 04/20/12 at 02:14:13 3F323D3036216164530 wrote:
Thanks! I wish I had a fraction of your carb tuning knowledge :) |
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Title: Re: Finally chopped Post by mcentric on 04/21/12 at 12:59:13 Got a little more work done at in my small home workshop. http://p1.bikepics.com/2012/04/21/bikepics-2387627-full.jpg My gass gauge is done. Now I just need to weld the threaded bungs in the tank http://p1.bikepics.com/2012/04/21/bikepics-2387624-full.jpg http://p1.bikepics.com/2012/04/21/bikepics-2387626-full.jpg Because of the steep angle of the tank, I need to move the petcock all the way to the back and angle it slightly forward for the filter to clear the top of the tank. I bought a really cheap moped petcock that came with a poorly cast 16mm fine pitch left hand thread!! As I don't have a 16mm fine pitch left hand tap, I decided to turn the existing threads down and cut some new regular pitch M12 threads. http://p1.bikepics.com/2012/04/21/bikepics-2387628-full.jpg http://p1.bikepics.com/2012/04/21/bikepics-2387629-full.jpg http://p1.bikepics.com/2012/04/21/bikepics-2387630-full.jpg http://p1.bikepics.com/2012/04/21/bikepics-2387633-full.jpg http://p1.bikepics.com/2012/04/21/bikepics-2387634-full.jpg http://p1.bikepics.com/2012/04/21/bikepics-2387636-full.jpg http://p1.bikepics.com/2012/04/21/bikepics-2387638-full.jpg Next I need to make a new "spigot" on the output side as this one is way too small for the gas line to the carb. I'll also try to bore out the inside a bit as I'm a little worried if it has enough flow to feed the carb properly. Mike |
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Title: Re: Finally chopped Post by DNLMusik on 04/24/12 at 05:39:06 I applaud you talent and work! |
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Title: Re: Finally chopped Post by mcentric on 06/12/12 at 12:16:00 Well, once again time has flown away from me, but I'm finally nearing completion. The gas gauge bungs were welded in http://p1.bikepics.com/2012/06/12/bikepics-2414743-full.jpg http://p1.bikepics.com/2012/06/12/bikepics-2414745-full.jpg http://p1.bikepics.com/2012/06/12/bikepics-2414746-full.jpg http://p1.bikepics.com/2012/06/12/bikepics-2414747-full.jpg The tank was sanded and primered http://p1.bikepics.com/2012/06/12/bikepics-2414748-full.jpg http://p1.bikepics.com/2012/06/12/bikepics-2414749-full.jpg And here it is more or less assembled. Still have some electrics and painting to do, but now I just want to ride it :) http://p1.bikepics.com/2012/06/12/bikepics-2414752-full.jpg Mike |
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Title: Re: Finally chopped Post by mcentric on 06/12/12 at 12:26:31 Here's a short clip of it running http://youtu.be/WTnUVDCkUo8?hd=1 |
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Title: Re: Finally chopped Post by Smokestack on 06/12/12 at 15:09:01 Killer. I wish I had a "small workshop" like yours. |
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Title: Re: Finally chopped Post by justin_o_guy2 on 06/12/12 at 21:27:46 Some clever answers to roadblocks.. nice lookin setups, th shop and the bike. |
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Title: Re: Finally chopped Post by teabowl13 on 06/13/12 at 06:55:43 From a guy who's not a big Bobber fan: That's a fantastic job. I love your attention to detail; especially like the twisted struts that hold the rear fender and how you used the same material to make that tiny little tower that bolts the rear end of the tank down! That's sweet! You gotta get a close-up shot of that. The whole tank is very clean, and smartly done. That's one classy bobber. NOW GO RIDE IT!! ;D |
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Title: Re: Finally chopped Post by RpNSht on 06/13/12 at 10:37:43 you're bike is awesome. great job whats the filter used for the motor breather shown in the second and third images? 5C787A70747D110 wrote:
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Title: Re: Finally chopped Post by WD on 06/13/12 at 13:00:24 What's the address to send mine to? Really liking how yours came out, other than I run a full rear fender (FLH Shovelhead replica) and 15" apes. Should just donate it your class for them to finish, even have a 4.75 gallon fuel tank for it that needs to be Frisco mounted like your tank... Great work. |
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Title: Re: Finally chopped Post by mcentric on 06/13/12 at 13:52:02 0A3436323C2A2D383A32590 wrote:
Thanks :) My home workshop is actually tiny, but the workshop at work... not so much ;) |
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Title: Re: Finally chopped Post by mcentric on 06/13/12 at 13:52:34 4C5355524F4879497941535F14260 wrote:
Thanks :) |
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Title: Re: Finally chopped Post by mcentric on 06/13/12 at 13:57:05 4D7C787B766E75282A190 wrote:
Thank you very much :) The lower tank mount was pretty much a hack-job of necessity :D The tank was hitting the frame, and the angle of the tank was limiting the fuel capacity even more than it is now because of the large filler hole and it's placement on the tank. http://p1.bikepics.com/2012/04/13/bikepics-2382919-full.jpg |
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Title: Re: Finally chopped Post by mcentric on 06/13/12 at 13:59:26 49565B5B525D565F574C4D4A4B504A503E0 wrote:
Thanks :) It's just a cheapo aftermarket car crank case breather filter http://www.biltema.no/ProductImages/33/large/33-283_l.jpg |
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Title: Re: Finally chopped Post by mcentric on 06/13/12 at 14:06:26 6675310 wrote:
Thank you :) Even though I have the greatest students ever, I can't really let them get any credit on this one :D They haven't been involved in this build at all... even though some certainly had opinions on the build. Most of the work was done in the school workshops, but after hours and during weekends. It did appear, though, that it inspired a couple of them to start planning their own builds :) |
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Title: Re: Finally chopped Post by lch2 on 06/13/12 at 16:49:34 Great work, congratulations |
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Title: Re: Finally chopped Post by Ben03Savage on 06/14/12 at 05:05:16 Great Job! |
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Title: Re: Finally chopped Post by greenmonster on 06/14/12 at 14:40:19 I would kill to have a lathe and milling machine at home. Love the look you've got there, the fuel gauge is my favorite. How quickly do you go through the top "half" of your tank? |
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Title: Re: Finally chopped Post by mcentric on 06/15/12 at 15:02:08 272823794B0 wrote:
21060D5350300215020406630 wrote:
Thanks :) |
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Title: Re: Finally chopped Post by mcentric on 06/15/12 at 15:05:34 4D584F4F44474544595E4F582A0 wrote:
Thanks :) I still have some electrical issues to sort out, so I haven't tested the milage I get out of the new tank. But I can tell you right away that it will be pathetic :-/ My new seat will have my butt and back screaming for mercy long before I can ride a tanks worth anyway ;D |
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