After making the seatpan and seat I had some left over glass cloth and resin so I decided to try making a luggage rack to replace that useless pillion.
Below are some shots of the fiberglass form I made and the finished product. The actual work was straight forward and pretty simple. No special tools were needed.


I used a sheet of foam core and some Elmer’s glue to make a form to lay glass cloth over. The general shape was made with the foam core and follows the curve of the fender. The foam core was pretty close to the final shape that I wanted and then cleaned up with Bondo. Once the form was completed I melted wax over it to prevent the resin from bonding to my form.

I made the fiberglass blank oversized because I wasn't sure exactly how much clearance the seat was going to need.

I used cold rolled bar stock (Home Depot) to make the mounting hardware. It mounts just like the original so it is a matter of one bolt to remove. It's amazing what you can do with a bench vice and a couple of hammers.

Once the steel was glassed in I could cut it down to the correct size for my needs. The edges have a six gage  wire  glassed in between the holes to prevent any possible tear out of the glass.

I like the flow of the line and I can finally paint that fender!
What do you think?

Another creative mod from a Savage owner! Well done yerself!

justin_o_guy2 wrote on 02/18/11 at 03:29:09:


I like the look but I might change it for a supertrapp at some point...If I find one 'cheap' enough.

JohnBoy wrote on 02/18/11 at 06:24:59:




If performance is the goal, the TRapp is a fine choice. IMO, the best lookin muffler on these things is the Dyna & thyre cheap. You mite even try one & see if it makes ya happy. If not, you didnt lose much $$$.

that's awesome!!  good work man!  love your bike, not a fan of straight pipes but that's the only thing I don't like

RoadKill?