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General Category >> Rubber Side Down! >> Made in Transilvania, the rebuild of a 1992 Savage
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Message started by paulmocan on 02/16/14 at 02:00:22

Title: Made in Transilvania, the rebuild of a 1992 Savage
Post by paulmocan on 02/16/14 at 02:00:22

I've been part of this forum for a while now and love it. I would like to start by thanking the people who started this website, because if you need to know anything about this bike, you find it here. Thanks.

I bought this 1992 bike in february 2011 for about 1780$, and loved it. The price may seem a bit high, compared to the prices you have, but here it is an OK price. It already had some custom parts on it as seen in the pic. The bike had saddle bags, but I removed them.http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_0078.jpg
After a while I started working on it, and made some small mods. I removed the licence plate bracket/fender, and made a vertical one, bolted to the rear fender. Here is a picture.

http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_8084.jpg.
This is the background of the bike.
Constantly looking at other bikes, I started thinking of how I can modify it to look better. I was contamplating with the Ryca CS-1 build, but it is hard/expensive to get the parts here (Romania). Looking around for some custom savage's, I came across this bike and it just made sense.
http://pictures.topspeed.com/IMG/crop/201308/suzuki-savage-bobber-husz-01_600x0w.jpg
So I decided to start taking my bike apart.
http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_7203.jpg
After removing the rear seat and the rear fender, I went ahead to remove the battery and the airbox. I will go for a K&N RC-2880 air filter.
This is a picture of the progress.
http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_7211.jpg
I ordered a black dragbar, and I'm planning on getting some black bar end mirrors.
Not having time to work in the workshop, I started sketching the seat. I use google sketch-up on a daily basis, so here goes the 3D. I started with some measurements on the chasis, and then overlaying them on the actual picture.
After that some drawing, and this is how far I got so far. I plan on working on this design more, and cut these "ribs" out to make a full size mockup. After I have that I will think on where to go next.
http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/Savage%20seat%201.png http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/Savage%20seat%202.pnghttp://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/Savage%20seat%203.png

So? What say you? :-?

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by Serowbot on 02/16/14 at 06:41:45

I like what you are going for...
Keep sending the pics as it progresses...

I think you are the first Transylvanian member...
Cool!... ;)...

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by gizzo on 02/16/14 at 13:45:31

Should look good. I like the seat style. Are you planning to lengthen the swingarm like the sled in the third pic?

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by ToesNose on 02/16/14 at 14:14:34

Very cool Paul, keep us posted!

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by paulmocan on 02/16/14 at 14:16:35

564C484A4B75445751574C414240250 wrote:

Should look good. I like the seat style. Are you planning to lengthen the swingarm like the sled in the third pic?

I hope the seat will be the "piece de resistance", but will know more later this week, after I have time to build the mockup.
Do you think the swingarm was lengthened? From my measurement, based on pictures, it should be the exact same length as the stock one.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by old_rider on 02/16/14 at 20:10:53

Looks like the front tire is taller, making It look like the front is longer.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by PinkHelmet on 02/17/14 at 11:34:19

Fain[ch259] idee! (Nice idea!)

In case you'll want to change your rear wheel to a taller one you should know that I've put on mine up to 120/90-17 without anything touching.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by paulmocan on 03/04/14 at 21:52:58

I just have to say that, Time just flies by.
I have a lot to do, considering that the riding season is right around the corner. I plan to get the bike done in the next 3-4 weeks. What gets done, great, all the rest must wait.
So, last week I took it apart all the way. Right now it is just the frame, the engine and the loom. Since I took the picture, I removed the rear wheel also.
http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_7385.jpg
There have been some speed bumps along the way. While I took it apart, two things stood out, the cam chain needs to be replaced, and the front fork inner tubes had to be sent to be straighten. (it seems that they bent sometime last year, when I let a friend ride it, and he crashed it. It was not that bad, and the bend wasn't visible until I took it apart.)
Here is a box with most of the 'big' parts, and all the nuts and bolts are in jars.
http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_7389.jpg
Now, my plan is to powdercoat a couple of things. Here is a picture of the parts.
http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_7393.jpg

I want to get the rear springs painted black, leaving the rest of the shock chrome. I want to get the front lower fork and the bottom part of the triple tree, the engine covers (I don't think I will put them back, but I might just as well have them black), the turn signal brackets and the rims.

I have been following a thread about sand blasting and powder coating laced rims, but I didn't find a straight answer. Did anybody do it? How did It turn out?

If you have suggestions about the parts that I want to get powder coated, or any other part of the build, please shoot. This is my PLAN, but plans can change.
Please advise.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by S-P on 03/05/14 at 19:42:29

I LOVE that big front tire! Obviously not stock. Any idea what it is and if it is a straight swap with the forks?

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by paulmocan on 03/06/14 at 09:10:23

I have no idea what the front tire on that bike is. I plan on getting a stock, on mine.
Today I made a bit of progress with the brake rotor. I plan on drilling it. I came up with a template and I will take it tomorrow to a shop to get it drilled. I started a new post on the Technical Documents section with details and link for download.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1394125675/0#0

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by verslagen1 on 03/06/14 at 09:28:55

looks pretty close to the pattern I do.
3/16" holes?

Most say to leave the edges square, but you do need to deburr and remove any raised edges.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by paulmocan on 03/06/14 at 09:30:56

my intention is to remove the small raised edge on the outside of the rotor, and by doing so get a clean deburr on it.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by Gheorghe on 03/25/14 at 05:53:21

Nice bike and nice idea. Definitely de-burr the holes in the rotor. I am actually in the process of doing this on my RYCA right now. Also, if you really want to improve the front brake, look into a steel braided brake line to replace the rubber stock one.

Ma bucur sa var alti romani pe situl asta. Succes la construit!

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by paulmocan on 03/26/14 at 14:26:03

3E2D3A3B24292F2D2679480 wrote:

looks pretty close to the pattern I do.
3/16" holes?

Actually the holes are 6mm in diameter.
I would like to apologise, for using something similar to your pattern, without asking you first. I hope I didn't offend you, or affect your operation. I posted a template in the Technical part, but I can take it down. I just wanted to share my experience. Here, in Romania / Transilvania / Cluj is very hard to get this kind of things done. If I was in the states I might have went your way, and have you drill the rotor. Here, you have to know a guy who knows a guy who has a guy who works in a factory, to get it done right.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by verslagen1 on 03/26/14 at 14:36:49

3D2C382120222E2C234D0 wrote:

I would like to apologise, for using something similar to your pattern, without asking you first. I hope I didn't offend you, or affect your operation. I posted a template in the Technical part, but I can take it down.

no need, you developed the pattern on your own, so did I and it's similar to many factory patterns.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by paulmocan on 03/26/14 at 14:45:26

I also worked on a different disk rotor, that's based on a KTM model. I adjusted the size and the mounting holes to fit the savage. I didn't get around at getting it cut, but If any of you are interested, let me know, and I'll be happy to send you the template.

http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/Disc Frana.png

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by paulmocan on 03/26/14 at 14:54:12

So, I'm back on track.
Things started coming together this week. Some very important parts arrived. The K&N RC-1250 Air Filter is finally here, the timing chain is here (I had to order a new one, because the old one was past due), handlebar, new tires, the parts got back from powder coating, etc... Busy week.
Here are some pictures. I got around at lowering the front by 55mm, and hopefully tomorrow, the engine will be closed, timing and everything aligned. I also modified the chain tensioner, adding an extra hole, but it is not in this set of pictures. I'm working with a friend, who is a KTM mechanic, on the tougher parts like getting the timing right. Here are some pictures with the progress.

http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_7424.jpg

http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_7429.jpg

http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_7432.jpg

http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_7431.jpg

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by verslagen1 on 03/26/14 at 15:37:19

when we discussed my disc pattern, there was some concern about having the holes too large. And I've seen similar discussions elsewhere.
That's why I used the 3/16" holes.

Those look substantially larger.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by Dave on 03/27/14 at 05:25:28

79687C6564666A6867090 wrote:

So.....what kind of metal do you have it cut from? Whenever I watch how they make this stuff in a factory, they always cut it from some kind of base material that is soft....then do heat treating to make it hard. I am not sure how you would get this done on a single part.

Title: Re: Made in Transilvania, the rebuild of a 1992 Sa
Post by paulmocan on 07/28/14 at 01:30:18

It has been a while since my last post, but I just wanted to share with you where I got with the project.
Here are a couple of pictures of what it looks like.
I will try to take things further in the next weeks, but nothing major until winter.
Cheers.
http://https://googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_8825.jpg
http://https://5faace393d477a86a1950665ca1978a7eeda814d.googledrive.com/host/0B3CoUn9dGkYfRlJxXzBrZzFfN0E/IMG_8832.jpg