Hello everyone
I am new to the forum so I´d like to introduce my savage route.
I am riding bikes since I am 16 (I´ll be 33 in the September). I always like older and classical bikes. My first bike that I bought as a teenager for my own money was bike from 1975 and I restored it completly. I learned me a lot.
Then I bought diferent bikes always classics or naked bikes.
After years I bought my "final boss fight" project bike that I started to rebuild - its Honda sc33 CBR919RR from 1998 and it is the most modern bike I ever wanted. During the years of rebuild work I tried to finalize my university degree studies, then my kids were born etc etc and I had never time to finish. So I gave it to my local motorcycle service guy to finish it and.... he has it already 5 yers and can not finish it too  
So during that time I bought another bike to have something to ride. And it is my SAVAGE!! finally. But I did not like the look... and sitting position so... I started easy rebuild  
It is not so easy as I thounght in the beginning but it is sloooowly moving forward.
So.
My bike is 1986 savage. 4 gears... old one.



Previous owner was 70 years old dude and bike rode like 10 kms in 5 years.
Paintjob was not original, handlebars were not original (installed dragbars), a lot of mess in electricity cables,... cheap old bike.
So first year I changed oil, repaired electricity, brkaes changed head plug seals etc.. just make it ride. And I love character of the bike. It is light, super simple and engine... by the feeling of ride it feels to me more like oldschool motocross bike (like form 1960s-70s) then chopper.
And I always loved look of classic bikes from 50s, 60s. Nortons, BSA, CB,.... And I always loved old cafe racers but in last few years I feel like everything is café, and sometimes it is too much.. so...
So I decided to make my Savage look more like something called Roadster.
Goals are clear, I have to fit differnt fuel tank, seat, move foot controls. I also want eliminate airbox, want to fit diferent muffler, handlebars and headlight. And in the end I have to make new paintjob.
What I can not do are things that are not easy or possible to make it road legal in my country. I live in Czech Republic and every 4 yers we have to go to oficial control with every bike to verify that everything is ok, working and legal.
So I can not change wheel size, I can not modify frame and change "overall dimesnions of vehicle". All part (mainly lights) have to be stamped by "E" mark for european homologation. Whan it will be finished it still will not be 100% legal but I have to try to discus with comisars.
So the rebuild I started with diferent handlebars.
First I shortened stems.


Original had long stems and the shape was drag bars.


I found band bars in classic shape with right width (to keep width of the bike).
I fit them and it was much better.


Ps.:I need to find out how to upload images and then I will write down what I already did on my bike  

Welcome to the Savage forum!  A young person that appreciates more vintage bikes!  Cool!

Your photos are visible, and I’m able to see them on postimage (when my fat thumbs don’t accidentally click on an ad).

I like your handlebars.  Classic and functional.

The other modifications you have planned seem reasonably simple, but I’m not a customizer so it’s easy for me to say that.  The gas tank will probably be the biggest challenge and you’ll have to decide what you want to do with the speedometer/odometer when you make that change.  EDIT: you’ve posted more pics with the Yamaha gas tank.

For a 1987, your bike looks great and seems to have been cared for quite well!  Enjoy your build!

One "smaller" task is the rear fender.

I bought super cheap stainless steel fender from china. I like the look but I could not realise how to bolt it to bike without frame modification.


It´s nice, but...

I did not want to destroy original fender by simple cutting it.. I wanted to keep it in shelve just for case of future possible "original state rebuild" for controls.
Time to make my own.
I am not so good in metalworking but profesionally I am composites specialist. Carbon fiber is my hobby since I am 15 and I also have master degree in it and now I work as R&D departement leader in aerospace production. And still I work a lot with carbon in my hobby workshop... (I make my own carbon bicycle frames etc)
So easiest thing for me was to make my own carbon fender. Just bcs I know How to do and it is much waaaay easier to make it then to use metal.
And I also can use scrap materials.
I did not want to make mould so I decided to laminate possitive shape on the top of original fender and use it as a mould.

Orange layer is just peel ply textile that is removed after the laminate is cured.


Unmoulding was pretty easy (I used only PVA as a release agent) and fender went out of pretty well.

The holes are there bcs I could not aply material in areas where are some metal thing on original fender. So I left the hole there and after unmoulding I covered it on top by several layers of carbon and let it cure again.

Weight loss is definitely not goal on this build but nice sturdy fender weights only around 300 grams.



I trimmed all edges and tried to fit it on bike. It fits and I can use original bolts holding fender, bcs shape is the same.
Then I just aplied kit, filler and ready to be painted. (I did not do enough photos)

In the last picture you can see template I use for designing underseat case. I will make it also from carbon.


And here is cone filter that fits to my engine

I need to be sure that there will be enough space for that under-seat carriage case and for the filter.

Cool.

ThumperPaul wrote on 08/05/24 at 04:49:24:




Thank you! I am not sure that I can be called "young person" anymore. But thank you for compliment