Greetings All,
I have completed my Savage build. Can't give enough credit for how this forum helped the process. So, much information, so many good builds, so many members willing to share their stories and experiences. Gotta say there wasn't one good idea already thought out and most of the time tried out, I didn't unabashedly poach. This extensive mod started last November as I was thinking winter would be a great time to meet the challenge. So been at this for 10 months. Life interrupted lots taking me away from the project and at times stealing the momentum. I would guess all told I have a good 4-5 months of work in the engine build and the frame, cockpit, fitting and fabing, and body mods.
The brain-trust composed of our moderators, grey beards, gurus and wrench turners was invaluable. Can't say enough about their willingness to share their collective knowledge and experience. So, credit where credit is due...the forum virtually built my machine, I just put my limited skills to work executing the fabrication and wrench turning in my way...ending in the completed results. Results that I must admit I am pleased with.
Let me first acknowledge ohiomoto. I read and reread and looked and then looked more at his build. What a great job. It inspired me to put my hand to the test.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1472222031/45. As inspiration goes I was super impressed with this Tempter build by Speedtractor in Japan:
https://www.autoevolution.com/news/speedtractor-t-61-catalina-special-a-lovel...Ohiomoto and I did a little personal communication via email. I purchased from him my tail light and seat (it was brown I had it reupholstered) he threw in a rear fender and some enging mounts. His mid-controls thread was super informative, too.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1487785879/30.
Nerdsport also gave us a fantastic build.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1487785879/30. He also was willingly responsive to some email questions I had. My mid-controls are a straight derivation of what he did. I think he sold his bike...too bad...except for whomever bought it.
Can't say enough about Lancer! Got my Wiesco piston, Web cam, VM36 jetting schooling and he pointed me to Thunder Products for the Intellijet, UFO, and Torque Wing just for starters. He talked headers, engine rebuild, engine oiling break-in, and more with me. Talk about a sharing guru. Tip of the hat. Also, the black RYCA shocks he gave to me back when he was cleaning up around his shop...thanks man.
Versy was my source for the cam chain tensioner, and engine plug. Recently he guided me to the right answer about a binding starter when I was ready to fire this Savage up. Smart guy...has a great command of the working of the Savage...kudos!!
How do I acknowledge all the input on chain conversion, tires, rims, wheels, oil, etc etc etc from all the members that found answers through trial and error so I didn't have too? Let's just say the "Search" tab got a real workout and never failed. Batman offered invaluable exhaust scavaging knowledge. Rutly chimed in on carb jettin. Bought those too cool black powder coated engine covers from Dave.
I have a ton of photos documenting the build. I will post some (probably too many) for the forum. If there's something a member wants more images of...just ask. If I got em I'll share em. Don't want to bore anyone.
One central theme was cost. I tried to reuse as much of the stock stuff as I could. Budget was guiding consideration...spent lots of cash anyhow...so tried to keep the costs down with eBay finds, scrounging, modify modify modify original parts and fabbing some of my own.
I think with so much done...I will do the images to tell the story from the front end of the bike to the back. This is NOT the order that I did the work...waiting on parts (like the tank) and generating a thought process to address the "how in the hell am I going to do that" made for kind of a fluid build.
Here goes:
At some point they all kinda look like this don't they?
I kept the 19" front rim but mounted a dual purpose tire I got off Amazon, Kenda K761 M/C 57H 100/90/19. I like it and how it rides...matches the rear. Matching tires for a front 19 and rear 18 limit to some extent what can be run.
Mounted a chrome front fender: I believe it was the Kawasaki 750 fender Dave posted about. I chose a black and chrome color scheme.
Shortend the front forks 2 inches:
http://www.chopcult.com/forum/showthread.php?t=7129and added fork boots.
I cut down, drilled and threaded the original 6" pull back handlebar risers to 2 inches and kept the original handlebars, clutch, brake and throttle controls. Mounted a RYCA mini tach and mini speedo with a highly modified RYCA dual mount
I searched months until I decided on a Suzuki 250T tank...thanks eBay. Moving the tank mounts and getting this tank to sit and look good was probably the easiest thing of all the fab work. It more less fell into place. Had to cut off the old mounts...used threaded rod to pass throught the frame to make the new mounting studs. I moved my Raptor fuel petcock to the new tank...couple a tricks there to make it fit and not leak...it's not leaking...that's a win!!
Engine came out of the frame for the new piston, new cam, new cam chain tensioner, new enging plug and probably a good 5-6 hours porting and polishing the head. So many threads on the head work with photos really helped.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1366785093 for example. Engine back in the frame and looking a that freshly work exhaust port.
Living in New Mexico finding someone to bend me a header with the ~1.60 ID and 33-35 inch length was tough. Most muffler shops DO NOT mandrel bend their pipe...which I believe is mandatory. However, after a national search and rejecting the buy pieces and curves and weld your own route (I can burn a hole in anything I weld and I cann't weld without a grinder if you get my drift) I found Wilson Custom Headers. Great people. I sent them my original header do they could calibrate their bending machine. They bent me two headers...one in a full 2 inches to get the bends correct and the one I mounted with the ~1.6 ID. I think it was $90. Then I sent the pipe of to Jet Hot Coating for a ceramic coating...another $90...but all great businesses to work with.
I did the chain conversion first. Plenty, I mean plenty of discussion and references to access gears and chain and installation on the forum...for example...
http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1174239333OK...since were about midships the mid-controls were somewhat of a challenging fabrication. I used cardboard templates to design my mounting hardware, 1" steel tubing to then attach the outside mounting plates for the levers and foot pegs. I jetisoned the front foot pegs and repurposed the buddy pegs after I modified them to bolt flush. My templates were taken to a local CnC machine shop to be cut out accurately. When I welded it all together and used the existing bolt holes to mount the piece...surprise of surprises...IT FIT the first time!!!
I used the original brake pedal and shift lever (no holes was instructions to the CnC operator...I had to have them during the mockup.
Added the Susuki GS650 Center Stand and this is what the mid-controls look like before mounting.
Getting them mounted and everything functioning was a different kind of horse. It all works flawlessly...that's another win!
left side
right side
Still a midships there's that new Mikuni VM36 with UFO. Torque Wing, Intellijet and Uni airfilter.
I chose to eliminate the battery box and air box. With all the forum disussion about batteries I chose to go with an LiFePO4 battery that is being made here in Las Cruces called SpeedCell...
http://speedcell.com/.
Weighs less than 3 pounds AND the company/manufacturer is less than 15 minutes from my house. Gotta admit kinda expensive. Mounted it up under my seat pan.
Built a subframe to get the line I wanted from front of bike to back of bike using the tank line and seat.
TOO BE CONTINUED.