SuzukiSavage.com - 1987 Savage Street Tracker build

TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #585 - 04/25/22 at 16:05:21 The inside diameter turned out just slightly smaller than the drill size for an M10 x 1.25 thread. The drill size is 11/32". After drilling out the ID and tapping the full length, it looks like this.
Back to top	20220425_1551221.jpg Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged

TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #586 - 04/25/22 at 16:05:59 Here is how all the parts look prior to assembly.
Back to top	20220425_1551121.jpg Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged

TheSneeze

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Re: 1987 Savage Street Tracker build
Reply #587 - 04/25/22 at 16:08:45

And here is the assembled result. Both the stock fork clamp and the modified insert will be powder coated. The short knurled shank protruding from the clamp looks fine to me. Once powder coated, it will blend with the clamp. With a little bit of labor I am able to reuse the stock front turn signal mounts with the aftermarket signals I bought. Cool

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Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker (destroyed by fire)
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribut

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TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #588 - 04/25/22 at 16:11:53 Yes, I realize I will no longer have the damping characteristics of the rubber stem. I'm running with it anyway...
Back to top	Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged

Edub Full Member Offline SuzukiSavage.com Rocks! Posts: 163 Arizona Gender:	Re: 1987 Savage Street Tracker build Reply #589 - 04/25/22 at 23:06:31 Improvise, adapt, overcome! That’s what my USMC drill instructor used to tell us all the time, worked well for you here. Looking forward to your continuing story, this is such a great project. Thanks for taking us along for the ride!
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TheSneeze

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Re: 1987 Savage Street Tracker build
Reply #590 - 05/03/22 at 10:25:23

My first go at thermoforming plastic. Using 1/8" thick ABS plastic sheet I set about making a seat pan. Interesting process, and my results weren't what I set out to achieve. Some waviness in the large radius bend. It won't be visible until you take the seat off the tail piece once it's finished. I am going to be working with Tuffsides to do the upholstery on this seat. Straight pleats in black leather, with blue stitching to accent the Royal blue bodywork.

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20220503_1014391.jpg

Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker (destroyed by fire)
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribut

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TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #591 - 05/03/22 at 10:26:48 This seat pan will bolt to the fiberglass seat/tail section. Still need to add the threaded studs to it.
Back to top	20220503_1014561.jpg Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged

TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #592 - 05/03/22 at 10:29:55 These are the studs I will put in the seat pan to attach it to the fiberglass.
Back to top	20220503_1027321.jpg Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged

TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #593 - 05/03/22 at 10:31:38 I picked up this two part adhesive to bond the studs in place. It will be under the stud heads and also over the top of them.
Back to top	20220503_1027491.jpg Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged

TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #594 - 05/03/22 at 21:41:25 Just found another savage near me for $40! Parts bike, but for that price I will try and snag it tomorrow!
Back to top	Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged

TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #595 - 05/04/22 at 13:19:31 I now own two Savages! I got another '86 or '87 (need to decode the VIN still). It's been down, missing stuff, broken stuff, etc. It has CA plate with a 1990 tag on it. Edit - this one is an '86. My Tracker is an '87.
Back to top	20220504_1049451_001.jpg Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged

Edub Full Member Offline SuzukiSavage.com Rocks! Posts: 163 Arizona Gender:	Re: 1987 Savage Street Tracker build Reply #596 - 05/04/22 at 19:18:44 Congratulations! How did you find such a great deal? I’m obviously looking in the wrong places.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4401 Honolulu	Re: 1987 Savage Street Tracker build Reply #597 - 05/05/22 at 12:23:35 Whoa!!! What a score.
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TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #598 - 05/07/22 at 15:51:08 I have been doing a lot of tinkering today. I am finishing up my seat pan so I can ship it off to the upholstery shop. I will be using Tuffside for the seat. After scuffing the surface, I covered the stud heads with the JB Weld plastic bond.
Back to top	20220507_1548141.jpg Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged

TheSneeze Serious Thumper Offline Posts: 1226 Northern Nevada Gender:	Re: 1987 Savage Street Tracker build Reply #599 - 05/07/22 at 15:52:18 The stud lengths had to be trimmed down to aid in installation, and the holes in the fiberglass had to be oversized a little.
Back to top	20220507_1548341.jpg Every twenty minute job is a stripped thread away from being a three day ordeal. '87 LS650h Savage Street Tracker (destroyed by fire) '86 LS650g Savage (parts bike) '81 Kawasaki KZ750e ELR tribut IP Logged