Thanks, guys. I've made up forwards for several different bikes now (Yamaha XS650, Suzuki 1400 Intruder, Honda Shadow 1100), so have had a little practice.
The brake side linkages are all new. Like I said, weather has been absolute crap up here, otherwise could have recycled the brake linkage and just cut up a brake lever for the stop. In fact, I was going to do just that. I'm attaching a picture of my first attempt. It would have been successful, too. Problem was that I made it too short! I found out after I tried to mount it that there just wasn't room for it, the clevis, and the pin between the exhaust header and the frame.
So, for second (successful) try, I started from scratch. I made up a shaft with threaded end and shoulder then added the grease fitting, and made it pretty much identical to the first try, but just a half-inch longer. If you look at that picture of the clevis, that's custom aluminum (out of billet!) piece with the integrated stop in it. The stop takes the place of that tang on the back of the brake pedal that prevents the pedal from coming back too far when you take your foot off the brake.
Full disclosure is that the part of the reason that I did it that way is that the brake pedal came out with a little bit of a sloppy fit. It's 0.007" too big on the internal bore where it mounts up. Excuses, excuses, I know, but I couldn't get the carbide lathe tool that I was using to cut the bore. In hindsight, I figure it was an aluminum cutting bit with a too-large nose radius. By the time I figured that out and switched to a good bit, I was a little oversize. The way the stop is set up, there is a little radial pressure, on it so that it will be less noticeable. Not that anyone else would ever notice anyway. Just a little bit annoying to me is all.
Overall very pleased with how everything turned out. The design as it looks very clean to my eye--much better than some of the others I've done. Probably the only bike that was easier would be that '99 Shadow 1100. Was able to reuse the pegs, brake pedal, and shifter on that one. Especially like how the brake lever came out. I have a tendency to make everything a little heavy and clunky, but the brake pedal is probably about right.
Last edited by GDI; 04-04-2018 at 11:26 AM.