Since the powder coat came back, I am now focusing on the bodywork so I can get that out to paint.  I originally made the side panels out of 18 ga. steel (.045" thick).  Once I had them on the bike, I realized it doesn't look right.  So I ordered some 1/8" aluminum sheet to remake them.  Every custom bike build has parts that are 2nd, 3rd, or even 4th generation.  This build is not different.  Once I get these thicker aluminum panels made, I plan on putting a 45 degree chamfer around some edges with a router.  These should look much better.  After the side panels are dialed in I need to take the tank back off and deal with the rust inside.  The rust isn't bad, and this is not my first go around taking rust out of a fuel tank.  My Green Monster had a very serious rust problem inside, so this one should be a piece of cake.  But I need to finish all the work with caustic chemicals before it goes out for paint.  The only thing going in this tank after paint will be fuel as to not risk the paint job.  The tank cover (speedometer hole) will need to be fabricated as well, but I will more than likely leave it bare aluminum to compliment the silver frame.

Thanks!

TheSneeze wrote on 06/11/22 at 11:17:14:

Wow, that’s beautiful! I’m familiar with Tuffside, but haven’t needed one (yet). What do they charge for a custom seat like that?

The width of the pleats I left to his discretion.  He added a nice touch by increasing the each pleat width as it nears the tank.  Top notch work!  Tracking says I will be thrilled beyond measure on Wednesday.  

Never having ridden a thumper before, I guess I will find out.  At this point, it's all about the build.  From what I have read on this forum these are not bikes suited to a long ride.  I have some amazing roads here being only 30 minutes from Lake Tahoe.  But being retired, I will see how much buzz I can handle.  The smallest number of four stroke cylinders in one bike that I have owned was a '70's Honda SL350 twin.  Other than that, it has all been in-line 4 cylinder sport bikes.  This Savage I bought because it had a '05 Honda CBR600RR front end on it that I wanted.  From the steering stem rearward I didn't care about.  That modern front end was worth more than I paid for the whole bike, and I got the stock front end with the purchase.  I considered this a free Savage.  It sat in the corner of my shop collecting dust for a couple years.  Then I saw some street trackers online.  Those looked really cool to me!  When I finally stumbled onto some RYCA pics of the Savage I was hooked.  Then I found this forum.  The rest, well, is turning into a really long winded build thread!  So glad everyone is so helpful on here, you all are really great motorcycle peeps.

I'm lovin your shop Sneezy.  The bike too.  But that shop, Nirvana.

Hmmm...  what are the Nevada state colors again?