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Hardtail Conversion (VV) (Read 1026 times)
T And T Garage
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Hardtail Conversion (VV)
01/18/17 at 15:49:19
 
Hi All,

My buddy and I have embarked on a new project - converting a 1996 Suzuki Savage to a hardtail.

We're going the Voodoo Vintage route - the weld on as opposed to bolt on.

Please feel free to comment/give pointers where needed - we'll be asking a lot of questions I'm sure.
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Re: Hardtail Conversion (VV)
Reply #1 - 01/18/17 at 15:52:44
 
The "Donor"

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« Last Edit: 01/19/17 at 05:45:05 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #2 - 01/18/17 at 15:53:39
 
The teardown begins.....

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« Last Edit: 01/19/17 at 05:45:59 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #3 - 01/18/17 at 15:54:33
 
Nothing but frame

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« Last Edit: 01/19/17 at 05:47:06 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #4 - 01/18/17 at 15:57:03
 
The cut frame

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« Last Edit: 01/19/17 at 05:49:35 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #5 - 01/18/17 at 15:58:18
 
Ready to cut the spine....

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« Last Edit: 01/19/17 at 05:53:52 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #6 - 01/18/17 at 15:58:57
 
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« Last Edit: 01/19/17 at 05:55:57 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #7 - 01/18/17 at 15:59:58
 
Here's the Voodoo Vintage kit:







Lined up - ready for tacking!

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« Last Edit: 02/07/17 at 12:59:20 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #8 - 01/18/17 at 16:03:58
 
Tacking!



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« Last Edit: 01/19/17 at 07:44:08 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #9 - 01/18/17 at 16:04:39
 
Christmas!  We got the frame back from the welder!

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« Last Edit: 02/07/17 at 12:59:47 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #10 - 01/18/17 at 16:07:19
 
OK - so I should point out that we took the recommendation of VV and had the frame welded by a pro.  This is not something you want to "practice" on.  Our welder did a pretty good job - and it was pretty cheap.

It's worth it to know that the welds are good - no second guessing when you're on the highway.
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Re: Hardtail Conversion (VV)
Reply #11 - 01/18/17 at 16:22:07
 
Since I didn't do it on the outset, I should tell everyone our intentions for this build.

We don't really want to do a standard bobber.  No hard pan seat, no coffin tank, no tombstone tail light, etc.  What we're hoping to do is "capture the essence" of a vintage BWM R35 or '51 Honda Dream.  At the same time, we want to try to do something modern - front and rear disk brakes controlled by one pedal with a proportioning valve, and to keep the bars as clean as possible (no levers - more to come on that).

What we try & set out to do is something that hasn't been done before.  Yes, sometimes there's a very good reason why it's never been done - because it's dangerous, or silly, or simply impossible.  But for us, it's doing something that challenges us as builders.  If it turns out the idea stinks - we'll abandon it.  We're doing this as a learning experience - a couple of guys hanging out in a garage, turning wrenches.

You might as well challenge yourselves - right?
Smiley
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Re: Hardtail Conversion (VV)
Reply #12 - 01/18/17 at 16:26:37
 
Speaking of doing something different - here's the rear wheel mod we did.  Our idea is to incorporate the same exact caliper and disk that's used on the front.  A "matched set" as it were.

As you can see, we've got some grinding to do, but all in all, a pretty nice job - and the holes are spot on for the disk.
We've found a great, local machine shop to help us.

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« Last Edit: 02/07/17 at 13:00:12 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #13 - 01/18/17 at 16:28:43
 
Time for a little mock up fun - fender blanks and all!

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« Last Edit: 02/07/17 at 13:00:38 by T And T Garage »  
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Re: Hardtail Conversion (VV)
Reply #14 - 01/18/17 at 16:30:32
 
This is the standard 15" rear wheel - just too darned low....

We're gonna have to go with the 18"  (live and learn)

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« Last Edit: 02/07/17 at 13:01:00 by T And T Garage »  
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