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Message started by Sax Man on 02/03/10 at 15:11:26

Title: Sax Man's rear signal mod
Post by Sax Man on 02/03/10 at 15:11:26

In an effort to make more room for saddle bags (which I don't have yet) I've come up with this modification to move the rear signal lights. It only requires fabrication of one simple bracket. Did not even have to cut any wires. Here is the procedure:

1. Unplug signal lights from under seat.
2. Remove fender rails and extract signal light wires.
3. Remove rubber base from light fixtures.
http://www.dagooder.com/paul/bracket/01%20rubber.JPG

4. Fabricate this bracket. I used 11/4" galvanized stock from hardware store. The dimension details are at the end of the post. I tried to be as accurate as possible
with my measurements but as usual you'll want to test fit and double check.
http://www.dagooder.com/paul/bracket/02%20bracket.jpg

5. Flatten one side of each of two 3/4" aluminum spacers (from hardware store).
http://www.dagooder.com/paul/bracket/03%20spacer.jpg

6. Using some quick set epoxy tack the two spacers to the bracket with the flat sides facing out. Be careful to align them properly as they must fit inside the license plate fixture when mounting the bracket.
http://www.dagooder.com/paul/bracket/04%20bracket%20&%20spacers.jpg

7. Mount the light fixtures to the bracket. I stuffed some foam in the ends of the fixtures for water proofing. I thought about using RTV but disassembly might be impossible if ever needed.
http://www.dagooder.com/paul/bracket/05%20bracket%20&%20lights.jpg

http://www.dagooder.com/paul/bracket/06%20bracket%20&%20lights.jpg

8. Remove the reflector from the license plate fixture and countersink the two holes.
9. Mount the signal light assembly using two flat heat 10x32 bolts.
http://www.dagooder.com/paul/bracket/07%20mounting.jpg

Here is what it looks like from the back side. You can add two nuts as I did later for extra security.
http://www.dagooder.com/paul/bracket/08%20backside.jpg

10. Carefully cut the bolts off of the reflector. I used a rotary tool, cutting a little at a time and cooling the bolt in water between cuts. If it gets too hot you will probably melt the plastic.
http://www.dagooder.com/paul/bracket/09%20cut%20reflector%20bolts.jpg

11. Using foam tape apply reflector to the license plate bracket.
http://www.dagooder.com/paul/bracket/10%20reflector%20adhesive.jpg

All that remains is to reconnect the wires. Route them along with the tail light wires up through the fender hole. It was a bit testy getting the wire ends through the fender hole but with a little silicone spray it can be done. Then just plug them back up and you are finished.
http://www.dagooder.com/paul/bracket/11%20finished.jpg

A couple more views.
http://www.dagooder.com/paul/bracket/12%20another%20view.jpg

http://www.dagooder.com/paul/bracket/13%20and%20another%20view.jpg

Here are the bracket details.
http://www.dagooder.com/paul/bracket/14%20bracket%20dimensions.jpg

Have fun

Title: Re: Sax Man's rear signal mod
Post by babyhog on 02/04/10 at 14:43:11

After I got home and started looking at mine, it appears that they changed that area a bit on the S40. Mine's an '06. Looks like they moved that reflector, so this modification should be easier! Woohoo
Don't know if your template will work as far as size, but I bet it still will...

Pics of mine, currently stock: (
http://i757.photobucket.com/albums/xx211/babyhog/S40/PIC-0504.jpg

http://i757.photobucket.com/albums/xx211/babyhog/S40/PIC-0503-1.jpg

Title: Re: Sax Man's rear signal mod
Post by babyhog on 02/11/10 at 07:37:24

Ok, my signals came in yesterday. I was a little nervous because they were inexpensive from Ebay - http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=360231720997&viewitem=&sspagename=STRK%3AMEWNX%3AIT .
But to my surprise, they are very nice chromed steel, look great, and I love them. But they are going to have to be mounted differently, because they don't have the stem post like the factory signals. I would either have to lengthen the bar, or figure something else out.
I think flush mount would be best, so I was thinking of just drilling 2 new holes in the fender, lined up with the back of the taillight and mounting them directly to the fender. The wires will reach into the side bracket so my connection will be more protected.

Anyone see any downside to this, other than the extra holes in the fender?

Here's what they look like... Mine is an S40, and I have Savage rear signals right now, but these match the front S40 signals better too....
http://i757.photobucket.com/albums/xx211/babyhog/S40/mc482.jpg

http://i757.photobucket.com/albums/xx211/babyhog/S40/PIC-0506.jpg

http://i757.photobucket.com/albums/xx211/babyhog/S40/PIC-0505.jpg

Title: Re: Sax Man's rear signal mod
Post by PerrydaSavage on 02/11/10 at 15:29:13

Those ebay directionals look great! I wouldn't drill the fender though ... the original holes in the chromed siderails should do ... these rails come off easily, so remove them and fit the short stem of your new signals should fit thru the holes in the rails then thread the signal light retaining nuts back on the stems on the inside of the rails. Fish wires thru original holes in fender like the original lights ... reinstall side rails with new signals all ready attached ...

Title: Re: Sax Man's rear signal mod
Post by EJID on 02/11/10 at 15:54:22

This is the method I was talking about: (I was considering these from the same vendor as well, but decided that I would like to go with LEDs)

http://img.auctiva.com/imgdata/1/1/9/0/9/4/webimg/283376463_tp.jpg

Title: Re: Sax Man's rear signal mod
Post by babyhog on 02/12/10 at 05:45:05

67686B66220 wrote:

I saw their listing with the chrome bar, but from their description, the holes in the mounting bar are too far apart... when I was thinking I would put them up under the taillight, instead of behind the license plate. Could drill new ones, I suppose. Or just go ahead and put them behind the license plate.

Perry -- they would look great in the original holes, but I'm moving them because of my saddle bags. I should have mentioned that.

Bigzuk, I think yours look fine, the pics are tiny though.... But I guess that's what I'm gonna do. Thanks all!

Title: Re: Sax Man's rear signal mod
Post by A-Bolt on 01/21/13 at 14:19:40

Did your mod. thanks, great look. :) J B weld dimes, tails out, in those holes where you put reflectors. awesome lookin . cheap too! $4 for tap,plate steel $3. I used hex head bolts and got nuts to fit in light marker. they don't move. thanks man :)