Ok Dave, thanks. I have no clue as to how a website like this works in terms of bandwidth, storage, server load, etc so I just want to make sure I am not taking more than my fair share of space with all the photos and such.

Would it be better if each individual "project" had it's own thread? ( re-locate the regulator on one thread, add LED lighting on a separate thread, saddlebag conversion to hard-mount on another, etc). When it comes to the search engine here, would it be easier for other members to find specific info on those projects if they were all in separate threads?

I've always been a MacGyver type. That is what kept me employed for the last 15 years. I was able to keep 50 year old shuttle presses and riveting machines going with bailing wire and hand made springs I never let a machine or fixture get thrown out until I had stripped it of useful parts. This "unique" way of doing things comes from being poor most of my life, and making use of what I had on hand. 20 years ago I made a CNC 3 axis desktop engraver from parts I scavenged from some old HP printers and some open source software off the web. I've made my own night vision scope from an old JVC camcorder.

When it comes to the bike, I'm kinda in the same mode. I dont have thousands of dollars to customize it, so I have to get "creative". Those vents on the battery box cover are from a Bayliner boat The whole re-location project cost me less than $20. I'd give my left nut to have access to a lathe and a Bridgeport again...but sadly that went away when I got laid off.

Anyway....I'm rambling. I just wanted to say thank you for the support and for giving me a place to get the information I need...and to share my experiences. I donate to the site when I can ( and I recommend that anyone reading this take a moment to donate $5 or $10 if you can). This site is a FREE resource that has helped hundreds of Savage owners better understand and enjoy our bikes.

Boogie_with_Stu wrote on 08/22/15 at 01:06:28:


I'm genuinely interested.  You can tell by the view count that I'm not the only one.  You've got 631 views as of this post.  I think that says something.  Keep posting, we're enjoying your progress.

Having said that, I like what you did with the battery box cover.  I'm eager to see it mounted.  I noticed you've got a lot of oxidation on the plastic housing around the lock.  You can clean that up nicely by rubbing it with Marvel Mystery oil and after you wipe it dry put some lemon Pledge on it.  It will look good as new.  Same thing with the plastic speedo housing.  Worked like a charm for me.

JutMan wrote on 08/23/15 at 05:10:18:


The stock battery provides lots of power for those arctic nights that some folks have to rid in, it provides enough power to turn over a cold engine with thick oil......and a battery loses power when it is really cold.  It also provides some ability for an older battery to still do the job as it's performance declines.

If you live in a warm climate you may be able to get by with a much smaller battery (both is size and amp/hours).  However it will not provide you as much ability to run the starter if you have a bike that doesn't want to start for some reason.  With a small battery you need to keep your bike well maintained so it starts easy (you should do that anyhow).

The late model bikes have a relay built into the wiring already that turns off the headlight while starting.

Arent Cold Cranking Amps more important than Ah capacity? Especially for starting?

I've worked with LiPo and Lithium Ion batteries before. They do have a much flatter discharge curve and can hold a charge for quite a long time just sitting on a shelf. My experience is with smaller batteries than the ones used in vehicles, but my understanding is that lead acid batteries hold up better to abuse. If you take a screwdriver and put it across one of our lead acid batteries, you get lots of sparks and a welded screwdriver. Do that with a lithium battery and you get an explosion.

I seem to remember a story about Lithium ion laptop batteries doing exactly that not too many years ago. I'm sure that with the advent of electric vehicles, the batteries and circuits are much safer now....but I cant say I would feel comfortable with a Lithium battery between my legs

Back to the saga

Pics of the modified battery box cover mounted on the bike. On the bench it looked a bit "gaudy" and big, but once mounted I warmed up to it. Almost looks like it belongs there.

Very slick.  I might suggest wrapping the connector and wires with black electrical tape to keep moisture out and to make them less visible through the screen.  That said, I like it!