SuzukiSavage.com - DIY forward controls

Ed L. Serious Thumper Alliance Member Offline "We All go a Little Crazy Sometimes" Norman Bates Posts: 2808 Sunny Florida Gender:	Re: DIY forward controls Reply #30 - 04/15/18 at 16:01:35 Good point, I bypassed the kickstand switch, it has a history of malfunctioning.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18314 Camp Springs, Kentucky Gender:	Re: DIY forward controls Reply #31 - 04/16/18 at 04:00:39 Ed L. wrote on 04/15/18 at 15:28:17: When the material costs and time are factored in I'm making under $20.00 per hour for my effort. Ed Does that include the time it takes for you to respond to emails and orders, box up the parts and take them to the Post Office? (Probably not).
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Northwood

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Re: DIY forward controls
Reply #32 - 04/16/18 at 04:57:21

Ed L. wrote on 04/15/18 at 15:28:17:

I'm not interested in starting a flame war, just trying to express what it takes to produce the forward control kits. When the material costs and time are factored in I'm making under $20.00 per hour for my effort.
Northwood, check you PM box for some build tips on DIY forward controls.
Ed

My guess; you are not in it for the money

I read your PM and I sent you a reply. Interesting reading, thank you.

Losing the kick stand switch wont break or make the deal. Its nice to have but I dont think I will miss it.

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Blade Full Member Offline Posts: 135 Sydney Australia Gender:	Re: DIY forward controls Reply #33 - 06/02/18 at 07:04:55 .
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Blade Full Member Offline Posts: 135 Sydney Australia Gender:	Re: DIY forward controls Reply #34 - 06/02/18 at 07:26:00 .
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Ed L. Serious Thumper Alliance Member Offline "We All go a Little Crazy Sometimes" Norman Bates Posts: 2808 Sunny Florida Gender:	Re: DIY forward controls Reply #35 - 06/03/18 at 16:00:17 Looks good how did you mount the kickstand?
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KY Bluegrass

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Re: DIY forward controls
Reply #36 - 06/03/18 at 19:00:43

Just a thought. In my business I have clients ask if they can get this or that done. At times their desires are pretty unrealistic. My usual response is "we can do pretty much anything you want....if your pockets are deep enough and you aren't in a hurry"

I also find that some clients want to make a reasonable profit, but apparently think their vendors, like me, don't need to. Some think the only thing they are paying us for is the physical cost of the product. Not my time or expertise or the years I spent getting to this level of expertise.

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Blade

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Re: DIY forward controls
Reply #37 - 06/04/18 at 02:55:11

Ed,

I placed the kickstand in position, marked out the boltholes then drilled the plate and bolted the kickstand on. I used 10mm aluminium and it is strong enough not to need bracing between left and right plates.

Build details are:

EXTENDING FORWARD CONTROLS FOR THE SAVAGE
PARTS NEEDED:
CONTROLS SET
10 MM ALUMINIUM PLATE (OR THINNER STEEL PLATE AS LONG AS NO FLEX)
16” LINK ROD AND SWIVEL ENDS
12” LINKAGE ROD AND SWIVEL END
1” HEAVY PIPE BRAKET
PLATE TO MATCH PIPE BRACKET
STAINLESS RIGGING PLATE (OR STEEL EQUIVALENT)
THREADED ROD (CAN BE STAINLESS)
STIFF WIRE
NUTS AND BOLTS TO SUIT

STEPS:
1. SUPPORT THE BIKE, REMOVE THE KICKSTAND
2. REMOVE CLUTCH PEDAL, PEG, CLUTCH ROD AND MOUNTING PLATE
3. REMOVE BRAKE PEDAL, PEG AND MOUNTING PLATE
4. REMOVE BRAKE CABLE AND ROD CONNECTED TO BRAKE DRUM
5. CUT NEW MOUNTING PLATES FROM 10 MM ALUMINIUM PLATE
6. DRILL OUT HOLES FOR MOUNTING BOLTS AND NEW PEGS
7. BOLT PLATES TO FRAME
8. MOUNT NEW PEGS AND LEVERS
9. CONNECT A 12” ROD BETWEEN THE CLUTCH PEDAL AND CLUTCH USING EXISTING CLUTCH CLAMP
10. SPOT WELD A 1” PIPE BRACKET (SPRINKLER PIPE) TO THE BIKE FRAME
11. BOLT A STEEL PLATE TO THE BRACKET AND MOUNT A CENTRE BOLT AS PIVOT POINT
12. ALTERNATIVELY FOR STEPS 9 + 10 – WELD A PIVOT BOLT DIRECTLY TO THE FRAME BEHIND OIL WINDOW
13. LOOSLEY BOLT A PIVOT PLATE TO THIS PLATE (STAINLESS RONSTAN RIGGING PLATE FROM SHIP CHANDLERY)
14. CONNECT A 16” ROD FROM THE BRAKE PEDAL TO THE PIVOT PLATE
15. CONNECT A 24” THREADED ROD FROM THE PIVOT PLATE TO THE BRAKE USING JOINING ADAPTER AND EXISTING BRAKE NUT
16. REMOVE THE BRAKE LIGHT SWITCH
17. MOUNT THE SWITCH WITH A 20MM WRAP AROUND CLAMP BOLTED TO THE BIKE FRAME
18. CONNECT THE SWITCH LEVER TO THE PIVOT PLATE WITH A SHORT STIFF WIRE
19. ADJUST LOCKING NUT ON THE BRAKE END OF THE THREADED ROD FOR CORRECT BRAKE ACTION
20. DRILL LEFT PLATE AND MOUNT KICKSTAND

I have photos of each part and step, let me know if you need any posted.

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Northwood YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 33 Denmark	Re: DIY forward controls Reply #38 - 06/04/18 at 06:46:05 That looks pretty cool, Blade. Why did you choose aftermarket controls? My frame is out for powder coating at the moment. Cant do anything before it returns.
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Blade Full Member Offline Posts: 135 Sydney Australia Gender:	Re: DIY forward controls Reply #39 - 06/04/18 at 22:10:41 Northwood, I decided that while I had the controls off I may as well put on a set that matched my hand grips. I went with these:
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Blade Full Member Offline Posts: 135 Sydney Australia Gender:	Re: DIY forward controls Reply #40 - 06/05/18 at 01:26:41 These controls "push" rather than "pull" the brake rod, so I made up this push-me-pull-you to change the direction:
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Northwood YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 33 Denmark	Re: DIY forward controls Reply #41 - 06/05/18 at 07:06:01 Blade wrote on 06/04/18 at 22:10:41: Northwood, I decided that while I had the controls off I may as well put on a set that matched my hand grips. I went with these: Wow thats some serious money. Waaay too expensive for me. I am stucked on stock Nice little detail on the pull-push brake configuration.
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SavageMan99 Senior Member Offline SuzukiSavage.com Rocks! Posts: 391	Re: DIY forward controls Reply #42 - 06/09/18 at 20:30:47 Any word on mid controls? Are you selling the plates?
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Northwood YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 33 Denmark	Re: DIY forward controls Reply #43 - 06/12/18 at 02:25:18 SavageMan99 wrote on 06/09/18 at 20:30:47: Any word on mid controls? Are you selling the plates? Who are you addressing, SavageMan99?
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SavageMan99 Senior Member Offline SuzukiSavage.com Rocks! Posts: 391	Re: DIY forward controls Reply #44 - 06/12/18 at 10:37:51 Whoever can help me lose the all in one peg / lever / brake / shifter / kickstand controls. I'd like have a twin leg stand under the bike, so it sits straight on the stand. I'd also like plain foot pegs. I'm going for a plain look. Painted parts suit me better.
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