SuzukiSavage.com - My 2003 Savage saga, for any who are interested

Boogie_with_Stu Senior Member Offline Look Ma, no hands! Posts: 280 Raleigh, NC Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #15 - 07/23/15 at 18:58:14 Ok, so T storms all day today and had a roof leak, so no time to play with the Savage...but I did have some pics from a couple days ago from the turn signal re-location effort. Started here....1" mild steel angle.
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Boogie_with_Stu Senior Member Offline Look Ma, no hands! Posts: 280 Raleigh, NC Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #16 - 07/23/15 at 18:59:01 No band saw in my work shed, so out came the trusty skill saw....
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Boogie_with_Stu

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Look Ma, no hands!

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Re: My 2003 Savage saga, for any who are intereste
Reply #17 - 07/23/15 at 19:03:01

I split the angle on the ends which left me with "ears". I then heated the steel and bent them over to box in the edges. No welder either unfortunately, but this isnt a structural part so I'm not too worried. 1/8" angle ought to be plenty strong enough.
I bored out the end holes to accept the stock turn signal stems..

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stem_holes.jpg

03 Savage, Pearl Novelty Black,Raptor mod, Boulevard seat, Rectifier mod -'07 Honda Nighthawk 250 stock

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Boogie_with_Stu Senior Member Offline Look Ma, no hands! Posts: 280 Raleigh, NC Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #18 - 07/23/15 at 19:04:09 Then located the threaded holes in the stems and drilled out the bracket..
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Boogie_with_Stu Senior Member Offline Look Ma, no hands! Posts: 280 Raleigh, NC Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #19 - 07/23/15 at 19:05:11 Bolted the stems in to check for strength....they seem plenty strong.
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Boogie_with_Stu Senior Member Offline Look Ma, no hands! Posts: 280 Raleigh, NC Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #20 - 07/23/15 at 19:06:31 Full assembly before cleaning up the burrs and sanding...
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Boogie_with_Stu Senior Member Offline Look Ma, no hands! Posts: 280 Raleigh, NC Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #21 - 07/23/15 at 19:07:19 Bracket painted pearl black after all holes drilled, tapped and cleaned.
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Boogie_with_Stu Senior Member Offline Look Ma, no hands! Posts: 280 Raleigh, NC Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #22 - 07/23/15 at 19:11:10 The bracket mounts to the existing aluminium license plate mount with 4 10-32 SS machine screws. I'll mount it up tomorrow ( weather permitting) so I can start the wiring process. Pic of the final mount with the license tag to follow.
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Boogie_with_Stu Senior Member Offline Look Ma, no hands! Posts: 280 Raleigh, NC Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #23 - 07/28/15 at 07:10:18 New turn signal bracket mounted up. I used some rubber grommets between the aluminium license plate holder and my new bracket to try and cut down on the vibration a bit.
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #24 - 07/28/15 at 09:18:54 Stu, That is a really professional looking job. Kenny G
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Boogie_with_Stu Senior Member Offline Look Ma, no hands! Posts: 280 Raleigh, NC Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #25 - 07/29/15 at 00:03:05 Thanks Kenny! Although I am really posting this stuff so that it may inspire/instigate/give confidence to guys who are VERY new to motorcycles (as I am)...it IS nice to get a complement.
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koehlerrk Junior Member Offline One cylinder to rule them all... Posts: 98 East of Keuka Lake NY Gender:	Re: My 2003 Savage saga, for any who are intereste Reply #26 - 07/29/15 at 11:45:22 That's almost exactly what I was hoping to do for a bracket on my bike... nice to see it's working out nicely for you.
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Boogie_with_Stu

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Look Ma, no hands!

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Raleigh, NC
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Re: My 2003 Savage saga, for any who are intereste
Reply #27 - 07/29/15 at 19:51:13

koehlerrk wrote on 07/29/15 at 11:45:22:
That's almost exactly what I was hoping to do for a bracket on my bike... nice to see it's working out nicely for you.

The black iron (Home depot) bends and cuts easily...so it was quite easy to fabricate with common tools. A couple of welds would have been preferred, but I dont have a welder (yet).

The end holes were made with a rechargeable drill and a "step" drill bit Cool

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03 Savage, Pearl Novelty Black,Raptor mod, Boulevard seat, Rectifier mod -'07 Honda Nighthawk 250 stock

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justin_o_guy2

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What happened?

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East Texas, 1/2 dallas/la.

Re: My 2003 Savage saga, for any who are intereste
Reply #28 - 07/29/15 at 20:42:42

I can appreciate the thought process and getting it done with so few tools and Still making it look good.
Start looking at grinders that will take a cut off disk.Go to Lowe's, look at the grinder wheel stuff. Look for the thin , metal cutting disks.. HF has grinders, but seems some require
Reshaping
of the spark shield and a bushing to center the disk.

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Boogie_with_Stu

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Look Ma, no hands!

Posts: 280
Raleigh, NC
Gender: male

Re: My 2003 Savage saga, for any who are intereste
Reply #29 - 07/30/15 at 10:22:55

Just..great minds Cool

Went out last night and got both a bench grinder and a 4" hand-held (with grinding AND cut-off disks).

I am looking into a wire-fed welder. I need something that works on 120 and a 20 amp breaker. after looking at lots of units, and reading about 300 reviews...this one seems to be the best bang for the buck, and would meet all of my needs.
http://www.northerntool.com/shop/tools/product_200632003_200632003

I have no access to 220 and there is no way I would ever do enough welding to warrant getting an electrician to set up a 220 line in my workshop. I have stick welded before....just really basic stuff and not very often. The wire fed machines take a bit more finesse, but for sheet metal, mild steel, and tube welding...this seems like it will do the job. It is also the ONLY welder in this price range/class that has a "cold" wire. The trigger feeds wire and turns on the power to the electrode. All of the Harbor Freight, Home Depot and Lowes machines I looked at had "hot" wire...meaning you could get an arc any time the power switch was on.

It certainly would have helped with the signal bracket.

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03 Savage, Pearl Novelty Black,Raptor mod, Boulevard seat, Rectifier mod -'07 Honda Nighthawk 250 stock

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