I've got the wheels off the gs450 and the sprocket on the rear. All seems good there.
Going to get the front rotor turned to 10.25 diameter, right?
Will need to shim it out for the caliper, ok.
Is it right to replace the gs450 wheel bearings with new gs450 bearings?
Front clutch side wheel spacers will need refitting, correct? (I plan on using the speedo drive and rigging the speedometer somehow from the 450).
Anything else I'm missing?

Where is the area??

Also, instead of starting a new thread for each question why not do a build thread so others don't have to ask the same questions?

Rear wheel bearings are gtg.
Front wheel bearings are loose on the S40 axle shaft.
Now to try to find a part number.

On the nice side, I've put a few hundred miles on the bike in the last month.

Is the only answer to cut it down?
Can the S40 disc be fitted?
Any oem disc that fits?
Machine shops are scarce here, and I've never got a building to set my lathe up in.

You can cut it down, OR, make a little bracket to move the caliper out a little to fit it. Or if you decide to make a bracket, you can get a dual piston caliper from a sv650 and double your front braking.
I used some 3/16 steel. Mount the front wheel and bigger disc with the caliper removed, Tape a piece of 14 gauge house wire to the outside (single strand, insulated) then set the caliper of your choice on the wire where you want it. Make a template of the bracket out of cardboard, then copy it in steel. The wire gives you the clearance you need, get a couple new bolts and metal lock nuts (brakes get HOT and can melt plastic)  Take off the wire, mount it up, and bleed the brakes and your all set, with MORE front brake.
No lathe required! Just a vice, hacksaw, drill and bits, a file to smooth it up, and a can of paint. Anyone that can run a lathe should be able to make-up a bracket in a hour or so.
Good luck!

I ordered a full set of gs450 brakes, and rear wheel bearings.
I can't afford to order wrong front bearings, if anyone has a part number for bearings that will convert the 450 to work on the savage axle.
Or, if anyone has put the gs450 forks on a savage frame.

I'd need to remove all three bearings ( I think) and get the same, but with the savage inside dimension. If I get it figured out, I'll post numbers here.

I've been looking up.bearing specs and according to the charts I found, both bikes take the same bearings.
I know that on the wheels I have, they are different inside diameters.
I will try ordering bearings to fit the savage and hope they fit.