SuzukiSavage.com - Forward Controls Update

Ed L.

Serious Thumper
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"We All go a
Little Crazy
Sometimes"
Norman Bates

Posts: 2808
Sunny Florida
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Forward Controls Update
01/12/06 at 16:20:52

Here's a quick update on the forward controls I've tackled, could of been riding this week but instead decides to get this
http://www.bikepics.com/pictures/500400/
which is a 15"x15" piece of 1/2 inch aluminium plate and did this to it
http://www.bikepics.com/pictures/500401/
with a metal cutting blade in a band saw(lots of fun, the plate cuts like butter Grin

) Never thought that old bandsaw could do such a nice job. Here are the forward controls mocked up on the bike.
http://www.bikepics.com/pictures/500403/
http://www.bikepics.com/pictures/500404/
http://www.bikepics.com/pictures/500405/
Next is the brake cable bracket which will be bolted on and the shift rod which wil be made out of 1/4 inch rod with the ends drilled and the tips of the stock rod brazed in the holes. I was sitting on the bike this afternoon and boy what a difference four inches make in leg room.
I'm between jobs right now (bored to he11) and am thinking about cutting out more of these, just wondering how many Savage owners would be interested in a set, not sure how much to charge yet, probably under $200.00, just wondering who is interested.

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Silver '02, clubman handle bars, Cobra headlight, Sportster muffler, K+N stock air filter, 152.5 main, Superbrace, oil cooler, 1/2 inch aluminium plate forward controls, spark advance, goes like stink

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SAMM Serious Thumper Offline No lay down crotch rocket for me Posts: 576 Portland Oregon Gender:	Re: Forward Controls Update Reply #1 - 01/12/06 at 19:08:47 You might think about selling a paper template when you get them done !!!
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mmosel Senior Member 2005 No Login Offline My bike is officially THUMPING now. Posts: 415 NW Oregon Gender:	Re: Forward Controls Update Reply #2 - 01/12/06 at 19:16:18 Great job, great pics! I wonder what the max length forward controls could be (on the Savage, of course) ?
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Jim_R

Ex Member

Re: Forward Controls Update
Reply #3 - 01/12/06 at 20:07:14

It only cost me 20.00 for all the metal I used for 2 sets. Of course that isnt alum. One thing u might want to note. The shift rod is reverse thread at the front and normal on the back. We removed the mount for the brake line and rewelded on the new plate. That way the lines didnt twist when u pressed the rear brake.

We also made a rear brake extension that looks like this

I I
I I
/ ^ \
I I I I

kinda like a fork. Looking good so far.
Also u might want to get a nylon locknut for the stock bolt that isnt the motor mount on the left side near the kickstand. Mine got loose somehow (maybe from the different distribution of weight) and I used a locknut just in case.
Good luck

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Ed L. Serious Thumper Alliance Member Offline "We All go a Little Crazy Sometimes" Norman Bates Posts: 2808 Sunny Florida Gender:	Re: Forward Controls Update Reply #4 - 01/13/06 at 06:19:19 I guess I'll forget about making a batch of them , the labor is what costs, not the material. I'll be happy to send out paper templates of this design for free. They will be tracings of the plates and I can include some construction notes to help.
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slavy Serious Thumper Offline smart cars for stupid people Posts: 710 Phoenix, Arizona Gender:	Re: Forward Controls Update Reply #5 - 01/13/06 at 07:33:35 Ed, I am sure , everybody will grately appreciate this !
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mmosel Senior Member 2005 No Login Offline My bike is officially THUMPING now. Posts: 415 NW Oregon Gender:	Re: Forward Controls Update Reply #6 - 01/14/06 at 01:58:08 If I had the extra cash I would probably buy a set - but I'm strapped after the holidays. I'm still curious, do you think one could have six inch forward extensions?
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torque Serious Thumper 2005 No Login Offline 2008 nightster,flat od green and black Posts: 748 rock hill,S.C. Gender:	Re: Forward Controls Update Reply #7 - 01/14/06 at 04:29:14 mmosel wrote on 12/31/69 at 16:00:01: If I had the extra cash I would probably buy a set - but I'm strapped after the holidays. I'm still curious, do you think one could have six inch forward extensions? mine are extendened 5 inches out and 1 inch down,u could go out anouther inch,but i think five is perfect.
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clueless-FSO Senior Member Offline Posts: 454 Birmingham, Al Gender:	Re: Forward Controls Update Reply #8 - 01/14/06 at 06:25:15 I have the skills, but not the toys to make the plates. More than willing to pay for them. Closest I got was highway pegs. Great looking work!! Let me know if anyone does want to sell a set. Thanks.
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Ed L.

Serious Thumper
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"We All go a
Little Crazy
Sometimes"
Norman Bates

Posts: 2808
Sunny Florida
Gender: male

Re: Forward Controls Update
Reply #9 - 01/14/06 at 07:13:17

Looks like the thicker aluminium plate gives some clearance problems with the shifter. I ended up cutting the sleeve that the pedal is welded on and used that piece as a spacer to move the pedal assembly in to clear the plate. The extra thickness also uses up more of the engine thru bolt's length than the stock setup. If I'm going to use the stock heat shield the mounting tubes welded to the frame will need to be trimmed by maybe 1/4 an inch. I also picked up two lock nuts for the long bolts, sometimes it is hard to keep regular nuts tight on aluminium. Fabricated the bracket for the brake cable, took a couple tries to get it right. So far, so good though Cheesy

.

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Silver '02, clubman handle bars, Cobra headlight, Sportster muffler, K+N stock air filter, 152.5 main, Superbrace, oil cooler, 1/2 inch aluminium plate forward controls, spark advance, goes like stink

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Jim_R Ex Member	Re: Forward Controls Update Reply #10 - 01/14/06 at 14:37:07 Cant you drill some recessed holes on the inside of the plates so they fit into the tubes welded to the frame? I would do this before cutting those tubes down because it would have to be a pretty precise measurement or ur heat shield might be too far in. This also might make ur heat shield angled instead of flush.
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sluggo Serious Thumper ModSquad Offline big singles lead, twins follow the pack Posts: 4744 moses lake washington Gender:	Re: Forward Controls Update Reply #11 - 01/14/06 at 14:49:20 great work guy. for once being short has it's advantages. why don't ya write it up for the technical section.
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Ed L.

Serious Thumper
Alliance Member

Offline

"We All go a
Little Crazy
Sometimes"
Norman Bates

Posts: 2808
Sunny Florida
Gender: male

Re: Forward Controls Update
Reply #12 - 01/14/06 at 15:45:31

I went ahead and cut down the mounting tubes where the long bolts go thru, taped it off and used a grinder, must be chrome molly cause a hacksaw just bounced off the metal. I was thinking about recessing the mounting points but didn't want to have the aluminium that thin. If I ever want to take the plates off the bike I'll just stack some washers to make up for the metal which I removed. Currently on my fourth brake cable bracket design. Was drilling a piece of 1"x3/16" flatstock and then bending it 90 degrees so it can be bolted on. Just realized that some angle iron would be soo much easier to work with and would look a lot better than a piece of thick flat stock that has been beaten into an 90 degree angle with a big hammer and a torch, hello design #5. Cheesy

. The heat shield is mounted on the outside of the plate so it shouldn't be a problem hitting the exhaust pipe, I'll worry about that after I am happy with the rear brake cable bracket.
Hey Sluggo, I'll start posting all this over in technical under the forward controls section. Need to take some pictures first. Congrats on being made moderator

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Silver '02, clubman handle bars, Cobra headlight, Sportster muffler, K+N stock air filter, 152.5 main, Superbrace, oil cooler, 1/2 inch aluminium plate forward controls, spark advance, goes like stink

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