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Message started by nickythegreek on 07/07/14 at 09:11:37

Title: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 07/07/14 at 09:11:37

Hello everyone, I am a 32 year old from Columbus, Ohio. I got my first motorcycle last fall after I had my last moped stolen, and I can't thank whatever jackass did that enough! My interest in motorcycles came from my father, who passed away from lung cancer a few years back. I inherited alot of motorcycle gear from him and wanted to finally put it to some use. I am a short dude (~5'3" and 130 lbs). So I purchased a '06 s40 from a local used dealership at an insane markup (lesson learned). I was between the honda rebel and the s40 as my first bike, both would be great starter bikes for a guy my size. Luckily I made the right decision and went with the Suzuki. I have tried to include links throughout this post to the exact items that I have used during the maintenance and modification of my s40. My Amazon Prime account has gotten a workout!

I mostly ride around with some Harley chopper friends, and their influence has been growing on me. They rent a little garage space (drone footage (http://instagram.com/p/nB9Y_2Ba5a/?modal=true)) at a local motorcycle shop/compound (Rice Paddy (http://www.ricepaddy.com/)) where we go to work on our bikes. Between this forum and their expertise, my s40 has taken over my life.

I wanted to start this thread so that I can share my experiences and photos with the community. I am a techie by nature, but wanted to expand my knowledge into mechanics and the s40 was the perfect bike to assist with that.

Prior to my s40, most of the mechanical work I have done was on my 3d printer. I am also working on some custom 3d printed parts for my bike as well that I hope to share with the community. I am also a Google Glass (http://www.google.com/glass/start/) Explorer, and hope to give back to the community by making some how-to videos.

I regularly share my motocamping and modding experiences on my instagram (http://instagram.com/nickythegreek).

And now for the photos...

This is my Tomos toptank that was stolen and set me on my current course.
http://distilleryimage0.ak.instagram.com/30e10a3a0eb611e388fb22000ae911cc_7.jpg

2 weeks later, I had myself a stock '06 s40 with 2500 miles.
http://distilleryimage10.ak.instagram.com/be279afa1ff811e3916922000a1f9043_7.jpg

First 3d printed mod for my s40 was a throttle lock. This little guy has been very helpful on some long trips. It seems like the forums are not setup to allow instagram video embeds, so click here (http:////instagram.com/p/md0e5OBawq/embed/)to see how this guy operates. If you have a 3d Printer, this design is freely available to use for non commercial applications by it's designer on thingiverse (https://www.thingiverse.com/thing:111272).

First mod I did to the bike was to replace the rear turn signals. I'll get to the front ones later this year. This was needed due to me dropping the bike after hitting a patch of oil in a parking lot and snapping the rear right signal... man those OEM signals are trash! I ended up going with these aftermarket turn signals (http://www.amazon.com/gp/product/B009OKUO58/) from amazon. They are still blinking double speed (I think due to me double-grounding them by accident). I'll have to fix that at some point. I got an AMAZING tip from a local savage owner that I do not think is documented on this site. You can get the above signals to mount up the stock rails real easy using a cheap 12mm brad T-nut (I got mine from Ace Hardware)! I bet this would work with many other aftermarket signals as well.
http://ecx.images-amazon.com/images/I/41uxXMYM9wL._AA115_.jpg

I got sissybar jealousy from all of my buddies choppers. Riding season was about to start and we had several trips planned. I needed a way to strap gear down and I am not really interested in cluttering up the bike with a bunch of big bags. So I picked up the OEM rails/sissy from a member of the forum for a good price.
http://photos-d.ak.instagram.com/hphotos-ak-xaf1/10249236_587145011393091_59408659_n.jpg

Time for my first long trip! We headed out to Kentucky for Ramble Tamble. This was an important test run for me, as I wanted to see how a stock bike handled this 4 hour trip so that I had a baseline to compare future modifications to. Prior to this trip, I went ahead and replaced the oil. After researching this on these forums, I settled with Rotella T6 (http://www.amazon.com/Rotella-550019921-Synthetic-Diesel-Engine/dp/B005CHT4W6) with Redline ZDDP Booster (http://www.amazon.com/gp/product/B00881GELC/).
http://photos-h.ak.instagram.com/hphotos-ak-xaf1/10326474_791862604158687_246701282_n.jpg

Next it was time to tackle the muffler replacement. I ended up using the Dyna w/Cobra t-clamp (http://www.amazon.com/gp/product/B000I59940/) & heat shield (http://www.amazon.com/gp/product/B000I5AR4G) following the guides on the forum. I shimmed it with folded aluminum foil after several failed attempts at the tin can method. Sexy camo leather tool roll by clawkeeper (http://www.clawkeeper.bigcartel.com/).
http://photos-b.ak.instagram.com/hphotos-ak-xaf1/916023_1450864881824097_438107128_n.jpg

We had a local motorcycle show here in Columbus called Pinned Ohio (http://instagram.com/pinnedohio) at the local bike compound. So I decided to use it as a chance to get better at flying my Parrot 2 drone. Ended up crashing it twice and causing some damage that I have not yet repaired! Clip1 (http://instagram.com/p/oIA_mcha0j/?modal=true) Clip2 (http://instagram.com/p/oICZoyha2U/?modal=true)

Next important mod: red glitter dice (http://www.amazon.com/gp/product/B000QT012M/)
http://photos-c.ak.instagram.com/hphotos-ak-xfp1/10358394_617345685027634_429314927_n.jpg

Goodbye front fender. Roadtrip to Apple Valley with my buddies. Ironhead, Evo, S40, CB750.
http://scontent-a-iad.cdninstagram.com/hphotos-xfp1/t51.2885-15/10413088_1419153958361554_248271605_n.jpg]

Google Glass footage (http://instagram.com/p/omOnDJBa0D/?modal=true) of us bumming around Columbus.

Road trip! Needed a taller sissy. Found an old sissy at Rice Paddy (http://www.ricepaddy.com/), cut it up and had a buddy TIG it to the stock sissy. Ditched the belt cover and right mirror. Replaced left mirror with slimmer one (http://shop.rycamotors.com/mirrors_c1.html) from RYCA. Removed badging from tank and side covers.
http://scontent-b-iad.cdninstagram.com/hphotos-prn/t51.2885-15/10349742_246157278919412_1724235983_n.jpg

Belt squeaking. Wanted to shave down the outer edge of the belt at a 45 degree angle with a dremel and attempt to realign read tire. Front brake pads need replaced. Went with EBC FA106 (http://www.amazon.com/gp/product/B00666G8AI/) pads. Gonna need a bike stand. Thank you forums!
http://photos-c.ak.instagram.com/hphotos-ak-xfa1/10387798_577883842331466_1891870791_n.jpg

Finally got the wife on the bike! Bell Custom 500 (http://www.amazon.com/Custom-Vintage-White-Helmet-Medium/dp/B00I544018/) helmet with Vega Echo Shorty (http://www.amazon.com/gp/product/B004FRY7J4/) snap shield.
http://photos-g.ak.instagram.com/hphotos-ak-xfp1/10369351_1441288919456878_2113988_n.jpg

Feeling pretty confident working on the bike now. Time to mod the air filter and rejet. Purchased Lancer's jetset kit, K&N RC-1250 (http://www.amazon.com/gp/product/B00062YO9K/) as well as a K&N 62-1090 (http://www.amazon.com/gp/product/B00029WXR2/r) vent filter for the crankcase breather hose. Don't forget to pickup the air filter service kit (http://www.amazon.com/99-5000-Aerosol-Recharger-Filter-Service/dp/B00029WYEY/) like I did. Ripped out the air box and rejetted to a 152.5 main, 55 pilot, 2 washers on needle. Completely stripped the nuts out of the fuel mixture screw, over torquing and snapping a battery case bolt and a front pulley cover bolt. Those are problems for another day!
http://photos-h.ak.instagram.com/hphotos-ak-xpa1/929132_339253112888415_1839384791_n.jpg

I really like how much space was opened up after removing the air box. The induction noise at 3/4 throttle on the pod filter is pretty nice but it does a whistle noise at around 1/3 throttle that I am not to found of.
http://scontent-a-iad.cdninstagram.com/hphotos-xpf1/t51.2885-15/10448848_1446870552237013_2038952036_n.jpg

Picked up a pair of Biltwell Keystones (http://www.biltwellinc.com/index.php?l=product_detail&p=54) from a swap meet for $20 that had been cut down an inch or 2. I'm thinking about taking off another inch from each side. I used the top ends of the stock s40 risers bar with some random 1" spacers I found in a spacer junk bin at Rice Paddy. I used a dremel to shave off the alignment pin in the controls so they would work with the new bars. They cleared the tank and no rerouting or cable replacement was necessary! (phew). I ended up replacing the grips with a pair of Chocolate Biltwell Thrusters (http://www.lowbrowcustoms.com/p3189/buy/m-c-parts/bars-risers-amp-controls/grips/1-quot-grips/biltwell-thruster-grips-chocolate-1-quot-/) (not pictured). I can almost call this baby a chopper now! I'd like to replace the risers or spacers to get another 1/2"-1" outta them for comfort.
http://photos-h.ak.instagram.com/hphotos-ak-xpa1/10499084_779408255444183_995031912_n.jpg

During the rest of the year, I have several other mods planned out. Next is ripping out the battery box and relocating to the exhaust rack. I have an EarthX ETX12A on the way. I purchased it from warpoffroad (http://www.warpoffroad.com/earthx-etx12a/) using the 10% discount code (AZOP10) that I found in these forums. After that, I hope to tackle slimming, reshaping and recovering the stock seat. I still need to replace the front turn signals and replace my destroyed fuel mixture screw so that I can continue to tune. I purchased a Raptor petcock replacement (http://www.amazon.com/gp/product/B00B3SGZ3O/) awhile ago, but havent gotten around to installing it yet. I'll probably fix my speedo rattle at the same time. I'd like to with some 4 over tubes, or maybe just switch out the front end so that I can do a 21" front tire... decisions decisions. None of this could of been possible without the guidance of this forum!

And now some shots from my Fourth of July weekend.
http://scontent-a-iad.cdninstagram.com/hphotos-xpa1/t51.2885-15/10522814_723731614340355_1747523102_n.jpg

http://photos-d.ak.instagram.com/hphotos-ak-xpa1/1598672_1637528913138867_1313083244_n.jpg

http://photos-f.ak.instagram.com/hphotos-ak-xpa1/10413896_514709401996381_295146618_n.jpg

http://photos-b.ak.instagram.com/hphotos-ak-xpa1/10453988_743396002369233_1189527012_n.jpg

http://photos-h.ak.instagram.com/hphotos-ak-xpf1/10471924_322676634557135_804877214_n.jpg

http://photos-c.ak.instagram.com/hphotos-ak-xpa1/10483478_746844325380098_584067652_n.jpg

We plan on hitting up a couple other events this summer, such as the lowbrow getdown (http://www.chopcult.com/news/blogs/save-the-date-folks---july-11-13-2014---lowbrow-getdown04-29-14-17-00-19.html) and hood bush (http://instagram.com/p/qIU1cbJ8UM/?modal=true). It seems I am normally the only Big Single in a sea of Harley choppers! I'll try and continue to update this thread with my mods, 3d prints and trip photos.

Title: Re: nickythegreek's s40
Post by Serowbot on 07/07/14 at 11:34:12

Cool stuff... Thanks for the pics...
Looks like a great place to be... 8-)...

Title: Re: nickythegreek's s40
Post by BalingWire on 07/07/14 at 14:33:33

Looks like you found a full bottle of ÜberCool and drank the whole thing! 8-) Love the Ohio swallowtail burgee; I've been flying one on a new 25' pole in front of the house for a year now.

Title: Re: nickythegreek's s40
Post by Smokestack on 07/07/14 at 18:20:18

Cool pics, man. Looking forward to more!

Title: Re: nickythegreek's s40
Post by Dave on 07/07/14 at 18:28:52

Cool.....a man enjoying his motorcycle and riding the wheels off it.

Don't let them go out of your life for 35 years like I did.....I missed a lot!

But I am back!

Dave

Title: Re: nickythegreek's s40
Post by Demin on 07/08/14 at 05:21:25

You won't be the only single at the Lowbrow Getdown.That's only about half hour ride for me.

Title: Re: nickythegreek's s40
Post by Pine on 07/08/14 at 06:41:46

Welcome to the ride...
I thihnk you out-WD'd WD.

I am so jealous fo the 3D printer work.. been wnating to play withone.. but too chicken to actually spend the money.

PS: Seems to me YOUR S40 is cooler than the HD's

Title: Re: nickythegreek's s40
Post by old_rider on 07/08/14 at 11:56:47

Lookin' good! Sounds like your summer is going to be filled with ridin' and fun!
Also a Glass Explorer here, how your heat shooting videos? mine heats up at about the 4 minute mark to where I have to shut it down.
Got the newest 18.3 update and battery life has improved tremendously, but the over heat on videos is driving me nutz.

Title: Re: nickythegreek's s40
Post by nickthe_human on 07/08/14 at 14:43:23

Looking good, Nicky! I follow on instagram as well, but its great to see and read the details of the mods.

And down here in Arkansas everyone rides uber large v twins and I am always the smallest dude on the smallest bike.

Title: Re: nickythegreek's s40
Post by nickythegreek on 07/08/14 at 19:34:39

36353D2B303D3C2B590 wrote:

I can drain the full battery if I am on the bike without a helmet. I don't do much long form recording though.

Title: Re: nickythegreek's s40
Post by WD on 07/09/14 at 09:19:39

5C65626978637E0C0 wrote:

Welcome to the ride...
I thihnk you out-WD'd WD.

;D

Naw, his chick stick isn't high enough...

Looking good so far NtG.

If you make it to the LowBrow get together, flip them the bird for me. Both parts orders I've gotten were crap. Levers shipped w/o cable end docking lugs (required, have to source them elsewhere) and the lenses for my rear signals melted (replaced them with glass lenses, again sourced elsewhere). Won't be buying much (if anything) else from them, can mostly get the rest of what I need cheaper, with lower shipping costs, from a vintage tractor parts house (fabric covered wire, real coil and plug lead, wiring connectors, seat hardware, etc). The rest from Motorcycle Superstore or J&P Cycles.

Title: Re: nickythegreek's s40
Post by nickthe_human on 07/09/14 at 14:44:11

that sucks WD. ive ordered some minor things: handlebars, grips, etc from them and had no issues.

Title: Re: nickythegreek's s40
Post by nickythegreek on 11/25/14 at 18:36:33

Snow has fallen in Ohio and it is time for the winter project. But first, some filler...

HoodBush was an awesome time.
http://scontent-b-iad.cdninstagram.com/hphotos-xap1/t51.2885-15/10483588_638844529556912_790739366_n.jpg

I ended up throwing on a pair of fabbed hard struts for the remainder of the summer.
http://photos-e.ak.instagram.com/hphotos-ak-xap1/1723377_1629816770578396_1650445568_n.jpg

Bike ran great all summer without issue, even after I laid her down twice. Buddies got an expansion on their garage space and I moved in.
http://photos-a.ak.instagram.com/hphotos-ak-xpf1/10732025_1512764615641976_616573079_n.jpg

Time to start tearing down the s40.
http://photos-e.ak.instagram.com/hphotos-ak-xpf1/10787831_556380691163196_2019505554_n.jpg

Naked frame and my voodoo vintage weld on hardtail.
http://photos-e.ak.instagram.com/hphotos-ak-xap1/923850_656828514436932_207352372_n.jpg

Frame cut and hardtail just resting for a little mockup before I headed home.
http://photos-b.ak.instagram.com/hphotos-ak-xaf1/10817620_1737554583135897_889259956_n.jpg

Hope to get the hardtail done soon and then I'm gonna be on the hunt for some more parts. Voodoo Vintage makes a Harley front end adapter that I am thinking about to allow a 21" front tire and open up my options. Hope to procure an 18" rear as well. I'll probably use tc brothers fake oil tank for the electronics.

I'll document the rest along the way.

Title: Re: nickythegreek's s40
Post by ToesNose on 11/26/14 at 03:47:26

Looks like you have a productive winter ahead Nickey ;)

Title: Re: nickythegreek's s40
Post by EJID on 11/26/14 at 08:09:36

Been following your posts on IG, looks like you've had lots of fun. Can't wait to see this conversion with the King/Queen seat as well. 8-)

Title: Re: nickythegreek's s40
Post by raydawg on 11/27/14 at 09:11:22

You made the right call.....

Out of necessity, two hour ferry line waits, to and from work on peak summer dates, I got a bike as they just ride to the front of the line.

I bought a new Rebel even before I took the class and got the license.

A stiff tepid rider at first, my paranoia kept me from hurt.
As I got a little more wear outside the center line of the tires, I began to become dissatisfied with the rebels ability.
After about a year I took it back and got the S40. Loved it from the first ride.
Now at 6 foot and 200 pounds, I am a wee bit bigger than you and doan look as cool as you on the thing.....
Which, bugs my wife more than me, as she tells me I should buy a bigger bike.....
I have considered it, but, after reading these guys who have had many bikes and why they are riding this gal, keeps my focus away from my uh, cool pride, and on my real needs ;D
With some metzlers rain tires on her I ride her all year long up here in the pacific northwest.

Title: Re: nickythegreek's s40
Post by DJGCWB on 12/03/14 at 15:38:58

Tuned in to this thread for sure!

Title: Re: nickythegreek's s40
Post by nickythegreek on 03/31/15 at 10:01:05

Quick update. My chopper has gone through a couple revisions during the building process. Tried out several tanks, fenders and bars. Most of my parts came from lowbrow, tcbros and some swap meets. I am running the stock rear tire still with a Norton fender that I need to polish up real nice.

Here are a couple of parts used in the build:
Fake Oil Tank for electronics (http://www.tcbroschoppers.com/electronics-tank-fake-oil-tank.html)
Ignition (installed on oil tank) (http://smile.amazon.com/gp/product/B00IAEVMK0/ref=od_aui_detailpages00?ie=UTF8&psc=1)
3 Position switch for headlights Low/Off/Hi (local auto store)
Biltwell Kung Fu grips (http://smile.amazon.com/gp/product/B0071XK7A2/ref=od_aui_detailpages00?ie=UTF8&psc=1)
Battery box (narrowed to fit my EarthX Lithium) (http://www.tcbroschoppers.com/tc-bros-holey-battery-box-for-1981-03-stock-sportster-ytx20-or-yb16.html)
Bungs for Tank and Seat (http://www.tcbroschoppers.com/threaded-bungs.html)
Gas Tank (I believe this was the one) (http://www.lowbrowcustoms.com/p888/buy/m-c-parts/gas-tanks-amp-accessories/custom-motorcycle-gas-tanks/cycle-standard-axed-2-2-gal-chopper-motorcycle-gas-tank/)
530 Gold Chain, 120 links (http://smile.amazon.com/gp/product/B003CJE7MS/ref=oh_aui_search_detailpage?ie=UTF8&psc=1)
Pangea Speed Airflow Bars (http://pangeaspeed.bigcartel.com/product/airflow-bars)
80's Le Pera King/Queen from a swapmeet (http://www.lepera.com/v4_rigid_detail.php?SEATID=222)

We were able to use the stock rear brake cable and modify the stock throttle cable to work as well.

The voodoo vintage hardtail conversion is not for the faint of heart. If you do not have welding/fab skills, you will be paying someone else to do some work (my wallet took a hit!). I had to have several things fabbed and some workarounds added. For example, the voodoo vintage frame appears to get in the way of the chain. We had to add a skateboard wheel to lift it up a bit. I was not happy about this, as I do not really like the look of this normally and the sound it makes gets to me. But my buddy found a great way to kind of hide it. In the end, we only ended up removing 1 link from the chain. We also needed to fab spacers for the rear wheel as well as a tab to hold the drum brake in place and a holder for the read brake cable. We are adding a rear motor mount as well for added stability. The frame also gets in the way of where the muffler normally sits. So I had to twist the header pipe out over the front peg a bit to get clearance for the dyna muffler (currently held on to the frame with a pipe clamp).

I got a chance to test her out at Giddy Up Texas (https://www.facebook.com/giddyuptexas) and ran into some other issues that I need to sort out. I can only give it about 1/4 throttle, anymore and the bike chokes and dies. I'm gonna do a complete dis-assembly of the carb and replace the spark plug this week. It has a down and dirty wiring job using alot of the original harness and 18ga wire.

This month I will be tearing it all down again to have some welds finished up, painted and re-wired. I'll update this thread with more photos (including close-ups) of the bike.

In the shop, almost done.
http://https://igcdn-photos-h-a.akamaihd.net/hphotos-ak-xpf1/t51.2885-15/10502674_885027674892359_1070930015_n.jpg

Trying to fix my carb issues on the side of the highway.
http://https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xap1/t51.2885-15/1530744_928251893885780_30229757_n.jpg

Title: Re: nickythegreek's s40
Post by Dave on 03/31/15 at 10:57:29

Welcome back....I wondered when you were going to come out of winter hibernation.

Your bike looks great, and most likely you just suffered some carb or wiring issues. Tell us more about that cone air filter...is the rubber part closing off the vent at the top of the carb inlet....or is it the same filter that worked OK last year?

If the skateboard wheel is noisy - maybe a small sprocket would be a better solution. Chains are really made to move around on sprockets where the rollers are doing the movement - not on a skateboard wheel where the sideplates are slapping into the plastic wheel. Skateboard wheels might look cool on the show bikes....but your bike is ridden and needs something that is durable.

Title: Re: nickythegreek's s40
Post by savskad on 03/31/15 at 11:29:40

That's some pretty badass work nickythegreek.

Part of me want's to do some modding to my bike, another part says leave it stock. I'm split on it. :/ Right now I'm riding on the excuse "it's still under warranty". I'll probably ride that out for about another 6 months, after that, who know's what I'll come up with. I look forward to seeing what the future has in store for your bike.

Keep the rubber side down, man.

Title: Re: nickythegreek's s40
Post by HovisPresley on 03/31/15 at 12:12:25

What a great thread, Nicky. Your bike is looking fantastic 8-) I look forward to the updates.

Title: Re: nickythegreek's s40
Post by FDM on 04/01/15 at 13:52:19

Nicky,
The bike looks great. Love the seat!

I'm interested to know more about the issue with the chain hitting the frame in that hardtail. You're not the first person to mention running into Something like that. I recently emailed David at Voodoo Vintage and asked him about it. He responded and said that he wasn't aware of any issue. He said that he's sold 75 of them and wasn't aware of any problem. If that's true then there must be a few more people lurking around with some experience on this? I'm assuming that you have the standard VV hard tail for the savage and that you lined everything up right down the center as he recommends?

I had the engine in my bike with the stock wheels and once I realized they weren't going to work I took it apart again. Wish I'd tried to put a chain on it before I did.

Title: Re: nickythegreek's s40
Post by nickythegreek on 04/02/15 at 08:38:23

I am currently running the ls650 VV hardtail (Model 33) (http://voodoovintage.com/hardtails.html) with stock wheels. The clearance is low, but I have not yet run into any issues... time will tell!

The issue with the chain is the bottom crossbar (which isnt in the 3d rendering on their site). If you go below it, the chain hits 2 parts of the frame. If you go above it, the chain only hits 1 part of the frame. When we ran into the issue, I started searching around for photos of other ls650 vv builds but only came across 1 that was finished and had the chain side viewable and they had the skateboard wheel.

I just purchased the sprocketed chain tensioner listed below to replace the skateboard wheel hack.

I also purchased some floorboards as well. I hope they will still have some room for my feet with the header tilted outwards to allow the dyna muffler to attach...

WELD ON CHAIN TENSIONER 530 SPROCKET (http://www.tcbroschoppers.com/weld-on-chain-tensioner-530-sprocket.html)
Universal Mini Floorboards (http://www.tcbroschoppers.com/universal-mini-floorboards-kit-fits-harley-passenger-or-driver-clevis-type-folding-footpeg-mounts.html)

Here are some of the other VV builds from our forums.

Blueknight's Bobber 2.0 (with jockey shift?!) (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1407200089/2)
Detuned (bored out, vs800 front end with 21" wheel, 18" rear) (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1395723490/0)
ChrisTech (chain with tensioner) (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1395013708/14)
FDM (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1421419365/0)

Members doing VV chops with no dedicated threads:
Finney138 (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1367592974/19#19)
axa (http://suzukisavage.com/cgi-bin/YaBB.pl?num=1367592974/0#6)

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by FDM on 04/02/15 at 11:23:24

I threw the engine back into my frame today and mocked something up with a spare rear wheel so I could see the chain clearance situation in person. Definetly not great. I'm kind of confused that David at Voodoo claims that he's not aware of it. Perhaps there was some confusion but I think I was pretty clear about it. I fully understand that these are not bolt on plug and play components however there's no way that rerouting the chain with a chain tensioner was the intended design. If he's really not aware of this problem he should be so that he can fix it. I will try and explain it to him again.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by WD on 04/02/15 at 11:33:25

The chain interference, too short backbone, too short rear stretch, is why mine is still a swingarm bike. The Ryca rigid conversion looks okay, the VV one looks great, both are too little.

If either one would make their kit long enough to run a 4.75 gallon Paughco FXR Mustang tank, and a real seat (12x13 inch K model sprung solo or similar instead of a Schwinn bicycle seat)...

Nicky, bike looks great so far. Feel free to truck it over if you get in a bind, I'll call in sick from my town job so we can finish it up.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by Art Webb on 04/02/15 at 14:20:52

51535A170 wrote:

(1) A picture is worth a thousand words, don't explain it, send him pics
(2) is the frame designed with the chain conversion in mind? If so, it's hard to understand him not being aware of the problem, since you always mock a build up when designing a weld on kit for an existing model

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by dhsmithh on 04/02/15 at 14:42:05

this thing is awesome! love it man

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by FDM on 04/02/15 at 17:02:47

Thanks Art, I just got it together with a chain today and took a couple of pictures. I will include them in the future.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 04/02/15 at 17:14:10

Your hardtail is missing the lower support bar (my fender is attached to it) that mine came with that causes my interference. Did you get the 2 piece "assembled" or the pro builders voodoo hardtail?

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by Dave on 04/02/15 at 17:49:33

Hey....I am not a hardtail guy....but it seems to me if that cross piece is in the way - you need to figure out a way to gracefully raise it up a little bit so the chain will clear. Top part of chain goes over it....bottom chain goes under it.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 04/02/15 at 17:57:08

It came that way from Voodoo, so one would assume that the design was intentional. We discussed moving it but came to the conclusion that it would interfere anywhere along the frame. Changing it to flat stock might of gave us a position but decided not to pursue it any further.

I was hoping voodoo vintage would be at Giddy Up last week and already planned on trailering the bike down to Texas for the event to ride around Austin. That way I could pick their brain about it in person. Unfortunately they were not able to attend.

764D4057464A51574C444956250 wrote:

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by Art Webb on 04/02/15 at 20:46:32

that looks like a lot of slack, especially with a hardtail (says the guy who never built one) would it still hit if you took up some of the slack, or do you need that much?

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by FDM on 04/03/15 at 04:50:54

So the piece that's giving you the problem is the round cross support and not the squared off peice that the downtube connects to? I'm using the standard 2 peice model 23 purchased 2/14 (since been changed to model 33 but David at Voodoo tells me the only thing he changed was the model #). On mine the cross supports weren't permanently welded into place they were squeezed in and just a little tap and they popped right out. The one in question was in place until just before I took that picture. The one on top with the seat mounts on it in the picture was the same thing. The chain could be tighter than in that picture. The only thing holding anything together there is gravity. There definitely needs to be a chain tensioner, either way it's a pretty long run and even if things were tight there's not a lot of room for error.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 04/06/15 at 19:34:35

Photo with chain installed.
http://https://www.bikepics.com/pics/2015/04/06/bikepics-2735074-800.jpg

skateboard wheel tensioner closeup.
http://https://www.bikepics.com/pics/2015/04/06/bikepics-2735075-800.jpg

I got the sprocket tensioner in today and hope to get it installed before next week.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by WD on 04/06/15 at 22:37:32

You are "supposed to" upgrade to an 18 inch rear wheel with the Voodoo kit... just saying... won't change where the chain runs, but it will keep you from grinding the lower rails away.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by Dave on 04/07/15 at 06:39:42

So does it ruin the look if you weld a vertical strut to the top and bottom frame rails (on both sides) in front of the fender...then weld in the lower cross bar higher so it is between the top and bottom chain? I believe that making a skateboard wheel spin at 10,000 rpm (or whatever speed) can't be a durable part for someone that likes to put miles on their bike like you do. Riding home in a pouring rain might just wash all the grease out of the bearings and leave you stuck (pack an extra wheel and bearings in your luggage).

It also appears that you could raise that cross bar to the top of the frame and get the clearance you need to have the chain go under the cross bar....and then just mount the skateboard wheel to keep the chain from hitting the frame when the chain bounces - but not in continual contact with the chain.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by old_rider on 04/07/15 at 10:05:57

As long as that chain is, you are going to have to have a side to side "whip" guide somewhere along the middle or even attached to the bracket with your wheel.
If your chain slides a little sideways, as close tolerance as you have, it will hit your bracket or your frame.
Some kind of "U" channel, to keep it from shifting....

LOL... and that's my 2 cents...

Looking good! Keep it up! 8-)

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 04/07/15 at 13:14:27

The chain is currently 119 links (only removed 1). The skateboard wheel will be replaced with this sprocket tensioner (http://www.tcbroschoppers.com/weld-on-chain-tensioner-530-sprocket.html) shortly. I just wanted to get the photos up so that everyone can see why it is a necessity with the voodoo vintage mk33.

I reamed out the holes in the floorboards yesterday with a small drill bit so that they fit the stock peg hex. It took some time, but in the end was a pretty easy mod. The shaft on them is a bit long which gives the left floorboard a bit to much rotational play for my liking. I will probably design and 3d print some sort of shim to take up the slack. The right one has more of a up and down play which makes the floorboard sit a bit on a downward slope and still has some rotational play in the horizontal axis like the left, but not nearly as bad. I will probably try and solve it with a 3d printed shim as well. If I get a good result with the 3d printed route, I will upload the files so that others can use them in the future.

Left floorboard:
http://https://www.bikepics.com/pics/2015/04/07/bikepics-2735218-full.jpg

The floorboards are of course much thinner than the stock pegs which should actually alleviate some concern about dragging them around corners with the stock wheels/vv hardtail combo. The bottom of the floorboards compared to the pegs probably add 1.5" of additional clearance.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by skull thumper on 04/07/15 at 20:03:31

Nicky,
I'm looking for info on puttinga king and queen seat on a stock 96 savage

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 04/08/15 at 10:04:29

skull,

That could be tricky due to the wiring and rectifier and weird shape of the stock fender. You would probaby need to relocate some of that stuff and switch out to a different fender or have a king/queen built up from the stock pan.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by skull thumper on 04/08/15 at 10:25:41

Any suggestions on what type of seat won't be has hard to put on I ride with my son onthe back and hate the stock seat.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 04/08/15 at 10:28:33

There aren't to many aftermarket seat choices out there. The only one that I am aware of that is an easy install and will add some comfort (and maybe some lift for the passenger) would be by Corbin. It will run you a bit over $300 new. Sometimes they popup in the marketplace on these forums.

Corbin S40 Seat (http://corbin.com/suzuki/ss40.shtml)

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by skull thumper on 04/08/15 at 10:34:27

OK thank hers a pic if what my bike looks like now but I'm changing the exhaust as we speek

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by Art Webb on 04/08/15 at 12:14:04

Nice ride! that;s quite a paint job

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by skull thumper on 04/08/15 at 13:01:53

Thanks I'm putting an upswept slash cur exhaust on her as soon as parts come in

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 04/21/15 at 08:26:07

Below is a photo of the modifications made to the voodoo vintage hardtail.

http://https://www.bikepics.com/pics/2015/04/21/bikepics-2737602-full.jpg

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 04/21/15 at 11:11:52

I spent about 4 hours on Friday grinding the rust and stock paint off my frame as well as my tank, battery box and oil can to prep for painting. I ended up doing this with some wire wheel drill attachments and a gator disc (http://gatorfinishing.com/product/paint-rust-remover-4-12-extra-coarse-1pk/) on a grinder. My wrists were killing me but I was happy with the results.

http://https://scontent-lga.cdninstagram.com/hphotos-xaf1/t51.2885-15/11142760_620495434718459_1864225670_n.jpg

My buddy painted it on Sunday.
http://https://igcdn-photos-d-a.akamaihd.net/hphotos-ak-xfa1/t51.2885-15/11116931_638510959627107_1126152053_n.jpg

And I spent Monday evening starting to put it back together. You can see the chain tensioner in place. I have to move the wheel ALL the way forward to get enough chain clearance to keep it bouncing off the spring on the tensioner.
http://https://igcdn-photos-h-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11117190_1435765696719855_847123855_n.jpg

I hope to finish up everything except the wiring in the next 2 days. I am using the stock clutch and throttle cable (Harley throttle housing with a little hex end/set screw adapter). I have a 42" front brake line on its way (6" over stock on my '06).

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by Dave on 04/21/15 at 11:24:37

It looks good!

I think you should have mounted the idler sprocket solid like the skate board wheel was.....or make the tensioner so there is no spring and the arm bolted into place.

I believe that when you let off the throttle and the engine compression brakes......the bottom chain is going to go into tension and it will pull the chain down and the chain will hit the tensioner spring.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by skull thumper on 04/21/15 at 13:04:09

Looks good I would put a springer front end on it.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by FDM on 04/22/15 at 04:45:55

It's looking great! Just curious if you think there's room to fit a 150 rear tire on that tail or do you think everything is tight already? It's the clearance between the tire and chain that I'm concerned with. I'm stalled on mine cause I can't commit to a rear tire size. It's either going to be a 130 or a 150. I did some number crunching and determined that the 150 should be possible but numbers on paper and then the way things actually come out can be different.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by Dave on 04/22/15 at 05:08:33

0F0D04490 wrote:

I'm stalled on mine cause I can't commit to a rear tire size. It's either going to be a 130 or a 150.

The stock rear rim is a 2.75 width. The 150 rear tire is going to be pinched on the narrow rim and it will have a tread profile that is too round for the most mileage and traction. The 150 tire should be on a 3.50 rim.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by HovisPresley on 04/22/15 at 05:53:48

Looking good 8-) I love the colour as well ;)

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by FDM on 04/23/15 at 04:24:51

Thanks Dave, I should have noted that I'm not planning to use the stock rim but a new 18" rim from Buchanans. My choice is between a 3.5" and a 4.25" rim and either a 130/90 or a 150/70 tire. I know what size rim both tires belong on its just a question of how the finished product will fit in the VV tail section. There are some tight clearances.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by wambr on 04/26/15 at 01:41:04

http://imgc-cn.artprintimages.com/images/P-473-488-90/60/6057/2T9D100Z/posters/charles-barsotti-oh-no-no-i-think-it-looks-great-i-was-just-wondering-do-you-use-a-ge-new-yorker-cartoon.jpg
it looks absolutely stunning! I really like it. everything looks perfect and the color of the bike is very "in theme".

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 04/27/15 at 07:19:45

Thanks wamblr.

FDM,
I am unsure about the clearance of a 150. But considering you will probably need to make your own spacers anyway, I would imagine that you could make it work.

So my first attempt at wiring failed pretty hard. I reversed some wires from the starter relay and think I might of blown it or my ignition. I was also able to turn on my headlight via a switch without having a key in the ignition. Gonna try and troubleshoot that stuff today.

http://https://igcdn-photos-d-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11111295_692469247542483_1587723545_n.jpg

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by work9to5 on 05/06/15 at 19:58:34

If you need help with wiring questions feel free to shoot me a dm. It's really hard to kill those starters, hopefully you havnt. Really like what you've done so far.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 05/07/15 at 08:09:54

So I've been chasing a gremlin for awhile now. The bike would just cut off when given throttle. It had us all perplexed but I finally got to the bottom of it. I started up the bike and then just lightly touched my key and the bike killed itself. darn faulty ignition switch! We had a Jeggs Universal Ignition Switch (http://www.jegs.com/i/JEGS+Performance+Products/555/11100/10002/-1) laying around, so I tossed it in and no more issue.

I came across another issue with my chain conversion. The chain would constantly rub on the top back mount for the belt pulley/front sprocket cover. This made an annoying sound while riding and cant be great for chain life expectancy. I ended up taking a dremel with a cutting disc and removing about a 1/4" of the mount so that it was back passed the chain. I can finally here my engine while riding now! My chain will occasionally slap unto the spring on the tensioner when engine braking, but there doesn't seem to be any wear on the parts.

http://https://www.bikepics.com/pics/2015/05/07/bikepics-2739968-full.jpg

The floorboards just weren't working out for me. So I am back to the stock pegs as well.

http://https://igcdn-photos-b-a.akamaihd.net/hphotos-ak-xpa1/t51.2885-15/11201731_481901581965057_382027093_n.jpg

http://https://igcdn-photos-h-a.akamaihd.net/hphotos-ak-xap1/t51.2885-15/11189217_1570352729913367_1319716634_n.jpg

I picked up this 1965 german leather ammo case from a flea market to use as my toolbox.
http://https://igcdn-photos-g-a.akamaihd.net/hphotos-ak-xap1/t51.2885-15/11199528_1664414893788198_2071843050_n.jpg

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 05/11/15 at 10:40:40

We left Columbus to head up to the Fuel Cleveland (https://instagram.com/explore/tags/fuelcleveland/) show this weekend. We had 4 shovelheads, a cb750 and a turbo kz900 along with my 06 s40 chop. My bike did pretty well until she got beaten down by the pothole friendly nature of Cleveland streets. One pothole smashed by brake light bulb and the next one on the way home caused my bike to backfire real bad immediately after.

My other buddy blew the coil on his shovelhead at the sametime and we just loaded them up a truck and drove back to Columbus. I was having issues getting fuel to flow into the carb (flows fine from petcock). After limping her around a little bit the fuel flowed better but I keep lagging and surging when I am on the throttle. Seems carb related, so I will be disassembling and going through the carb once again.

Ice cream is the key ingredient to a happy chopper ride and pivotal when waiting for on the shovelheads chase gremlins. One shovelhead lost his rear brakes while the other had some tranny issues.
http://https://igcdn-photos-a-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11240320_1438383073144376_262915914_n.jpg

Tyler's shovel ended up blowing his battery at 2am (2 other shovels would end up doing the same thing in the next 12 hours!)
http://https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11257977_469274833226212_1894568995_n.jpg

Dan's battery goes boom. Kyle leaves to go get Dan a battery and his blows up on the way. Sidenote, don't use cheap batteries with plates that will vibrate loose and destroy the cells.
http://https://scontent-dfw.cdninstagram.com/hphotos-xaf1/t51.2885-15/11256814_1593077290934156_1588451297_n.jpg

Right after I started backfiring like mad.
http://https://igcdn-photos-h-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11264302_840291389381887_1543172411_n.jpg

At least we magically ended up breaking down right next to where Kyle's brother lived.
http://https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11240755_1610427299204380_120154486_n.jpg

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by justin_o_guy2 on 05/12/15 at 14:42:02

I put padding around the battery on my four wheeler. Protecting it from the harsh ride has,besn a good idea. Hardtail bikes ride rough.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 05/19/15 at 09:52:41

So I was able to track down the issue that happened after I hit that pothole. When I hit the pothole my bike immediately started to backfire. I could idle fine and ride at low speeds, but it would continue to backfire under rpm load. It ended up being the connector to my pickup coil. The pothole loosened it enough so that the vibration from the high rpms would break the connections. Of course I didn't figure this out until after I rebuilt the carb and reseated the exhaust to remove any leaks. I'm just happy that it ended up not costing me anything!

I purchased a Fuji x100 to take some black and whites this summer. We had a chopper party, Pinned, here in Columbus and I was able to get some pretty cool shots.

My ls650.
http://https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xfa1/t51.2885-15/11311415_907855555903476_1170069817_n.jpg

My bad to the bone pup.
http://https://igcdn-photos-c-a.akamaihd.net/hphotos-ak-xfa1/t51.2885-15/11251394_1838910299668322_590628181_n.jpg

Buddy's Turbo Kawasaki 900.
http://https://igcdn-photos-d-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11282301_298148923798227_1979241608_n.jpg

Kyle kicking over his shovel.
http://https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11264257_1642081372690228_1646950017_n.jpg

This weekend we are going to Smokey Mountain Chopperfest (https://instagram.com/smokeymountainchopperfest_/) in North Carolina. Hopefully I wont have any trouble this time!
http://https://igcdn-photos-h-a.akamaihd.net/hphotos-ak-xpt1/t51.2885-15/11201639_873644746041919_218027312_n.jpg

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by clinton on 05/19/15 at 10:13:14

New guy here. Hey everybody I really could use some help here. The RCYA website says " close to stock gearing " about their chain conversion kit. Tells me nothing. There was a forum ( can't find it ) where people said, " go to dealer and buy front sprocket for bike blah blah, year model blah, blah and gave sprocket number of teeth, front and rear, various sizes for different ratios and which equaled stock pulley gearing so I could choose how far up or down to go. I also don't know how to post new question so I reply to nickythegreek. All help appreciated. :)

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by WD on 05/19/15 at 11:19:50

505F5A5D475C5D330 wrote:

You mean this thread... http://suzukisavage.com/cgi-bin/YaBB.pl?num=1174239333 I assume.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by yetimeister on 05/24/15 at 21:30:28

What did you end up doing for spacers for your rear wheel alignment man? im hardtailing mine currently and any ideas tips and measurements would be appreciated.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by 05ss45 on 07/30/15 at 20:31:00

Nice pics and cool bike.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by nickythegreek on 08/18/15 at 15:56:35

ended up losing my dyna on the highway and then left my gas cap at a gas station on the way to the lowbrow getdown.
http://https://igcdn-photos-c-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11243940_879846815442354_868586479_n.jpg

Hit up the marketplace forum and boogie_with_stu hooked me up with a new (unbent) right peg and a dyna in better condition than the one I lost. Like an idiot, I overtightened my rear axle the next day prior to our trip to Indiana for the Boogiefarm Clamjam. Ended up with some toasted wheel bearings an a goldish brake plate!
http://https://igcdn-photos-g-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/11264754_1652790555007686_1014685063_n.jpg

While I had to get there without a bike, the good times still ensued.
http://https://scontent.cdninstagram.com/hphotos-xaf1/t51.2885-15/11326126_1452912478369767_145704513_n.jpg
http://https://igcdn-photos-h-a.akamaihd.net/hphotos-ak-xfa1/t51.2885-15/11312468_603324066472671_977172909_n.jpg

New bearings arrived just in time for the chopper and skate event, SkateOrDieOhio.
http://https://scontent.cdninstagram.com/hphotos-xaf1/t51.2885-15/11850204_113329379018689_917779450_n.jpg
http://https://scontent.cdninstagram.com/hphotos-xpf1/t51.2885-15/1742353_979185342145438_372599653_n.jpg

Bike is running good! Decided to take the wife and pup out for some ice cream.
http://https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xfa1/t51.2885-15/11910107_390774161125412_843018144_n.jpg

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by Dave on 08/19/15 at 03:45:39

If you cooked wheel bearings from tightening the axle....you are missing a spacer somewhere. (Most likely the one behind the pulley hub, as it is easy to lose).

When all the spacers are in place the tightening force does not place any loads on the bearings....the load goes through the spacers and the inner bearing races. The ball bearings should not have any load from tightening the axle.

Check out this parts diagram, and make sure you have spacer #17 that goes in the backside of the pulley hub.

http://www.hondaofflorence.com/fiche_section_detail.asp?section=432158&category=Motorcycles&make=SUZUKI&year=2005&fveh=10118

Here is an example of what happens without the spacer:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1416252292/10#10

We meed to get that bike of your reliable so you don't miss out on the fun!

That SkateorDie thingy looks like you were in Cincinnati....and didn't call me! I am about 20 minutes from downtown.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by gizzo on 08/20/15 at 16:27:15

Big ups to you, Nicky. Impressive seeing actual miles being done on a chopper. That's cool. I couldn't do it. I'll cafe race my travelling. Keep the bobber for local rides. Your pictures are great. Keep em coming.

Title: Re: nickythegreek's s40 (voodoo vintage chopper)
Post by inglourioushoko on 10/11/15 at 01:34:46

Awesome pictures man. This is heart of motorcycling, captured right here.