Since I suck at posting photos, I'll have to post web addresses:
1.https://www.flickr.com/photos/196818005@N02/52461236877/in/dateposted-public/
2. https://www.flickr.com/photos/196818005@N02/52462021484/in/dateposted-public/
3.https://www.flickr.com/photos/196818005@N02/52462288178/in/dateposted-public/
4.https://www.flickr.com/photos/196818005@N02/52461237012/in/dateposted-public/
My bike has been through multiple guises in the years I've owned it. This version is likely the last.
No engine work, just this stuff:
18" front wheel, 16" rear cast wheel, re-jetted carb, Sportster seat raised 3",
DC Motive top tree with fork lowered 35mm,
12.5" rear shocks, ceramic-coated exhaust, Dyna muffler, Versy, steel-braided brake line, narrow superbar, tank/fender clearcoated with 2K.
If I go any further, it will be to the engine, but at 78, it's fast enough for me.
Re: the wheels: one tube tire is better than 2 tube tires, ha!
Cheers!

The best mod was installing the 18" front wheel and lowering the front end. Steering is so much quicker and at least as stable. Expensive but worth it !
I never believed the S40 was a cruiser, and in my mind I've proved it, by creating a 'standard'. Too bad Suzuki didn't agree!
Cheers!  

Looks amazing! I too agree the S40 is no cruiser, it can hold its own against sport bikes in the corners.

Didn't think of a build thread. Because I don't weld, everything is bolted together using flat bar etc. Spanned the dip in the frame using flat bar between the end of the tank and the frame 'horns' and 6 and 8 mm bolts. This raised the seat about 3". The tail box is narrow flat bar bolted to the fender location. No vibes, pretty stiff.  All the rest is pretty straightforward.
Cheers!
ps: for the 8 years I've owned this bike, it has never left me stranded, rarely ridden above 60mph as I choose rural roads.
Check out "sea to sky' on youtube for a taste of where I ride.
Cheers!  

It's not exactly honest to say I weld,but I do have a stick welder and mig, no gas,just wire,from Harbor Freight. If you have a 110 volt outlet and two square feet to spare,the mug is low buck and will do the job. You can drag up junk to practice on. And you gotta have a grinder. The Harbor Freight grinder disks disintegrate at an astonishing rate, slinging bits and pieces, and they smell bad. It's worth the money to get quality disks.
You should not be limited by not welding. Really nice job.

I have two,, Meh, little ten dollar Rattle can size extinguishers I use for anything small. Used them a few times, still have the juice in them. Regular extinguishers, you pull the trigger and it Needs to be recharged. I have a couple of ten pounders in the shop.
If you're concerned about the wiring, go to the breaker box and inspect what is coming in. Go to the nearest outlet, that is the shortest run of wire. Is it visible? Can you plug a good load in and watch it? Feel for anything getting hot?
Man, when I first got my torch I was so paranoid. Police the area,get a water hose staged, hold the torch and go through the motions and look for anything I might light up.
I understand being worried. That is reason to be careful and prepared.
Or, just don't take the chance.
Are you worried you would start a fire welding or are you concerned about the wiring not handling the welder?
They don't draw over twenty amps, IIRC. I'm pretty sure that is what I have in the breaker box out there. It's never popped a breaker. You can stop and inspect stuff. If I was worried about the wiring, I wouldn't just start welding and not look up. Welding on junk, just making it work and watching the stuff you are concerned with, stop, go feel around for hot spots,

Just remembered,,if you are just using wire,no gas, that shield at the end of the gun is just in the way. For me, getting the angle and hold off distance right is easier without it.

I certified four of the welders that worked for me for aerospace welding.  We were welding on Patriot missile parts for Raytheon, among other really cool stuff.  It' does take some practice.  Here is a TIG sample in stainless steel.

Very nice Zip.  I love the color scheme and the standard bars.  Congrats on a job well done.