I've always disliked the big blocky looking pillion seat and thought it just looked out of place on the otherwise nice looking savage.
So I decided to replace it with a piece that would cover the diodes and wiring (since I really didn't want to move all that stuff) and
give a more finished look. Here is what I did:
1. Made a mock-up out of cardboard
2. Cut and shape 3 main parts from aluminum
3. Test fit
4. Temporarily fasten 3 main parts with metal tabs and pop rivets
5. Temporarily fasten 2 mounting parts with pop rivets. The two support pins are temp fastened with small bolts from the other side.
Now we're ready for Alumaloy
6. Alumaloy completed and all temp fasteners removed. The rubber bumpers on the support pins are doorstop bumpers
from hardware store. Now ready for foam and leather covering
7. Covering completed. I chose leather because I was able to stretch it (the piece was from the belly of the beast) without having
to sew - lining up seams can be a pain. It's bonded to the aluminum with lacquer based contact cement.
8. I originally thought the forward mounting tab would be sufficient support for the front of the cover but it wasn't as solid as I wanted.
And since it was too late to add 2 more support pins I came up with this solution - longer bolts, lock nuts, doorstop bumpers
9. before .... NOT!
10. after....Yes!
There were quite a few steps involved but I just used what I had on hand and went with it (no doubt truckinduc could have whittled
this thing out of a solid block of aluminum in about 30 minutes!)
Note that this is not a seat, just a cover. I personally think 2up on a motorcycle is way too dangerous - riding alone is bad enough.
Next time I remove the rear tire (perhaps for chain conversion) I will remove the rear foot pegs.
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