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Discussion Starter #1
Weather has been just awful up here. I usually think of getting some good riding in before the end of March, but have only been out once. On the plus side, have had plenty of shop time to work on the Vulcan. Here are some pics of the forwards I made up.

GDI
 

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I like that, hard to tell how you did the brake side linkage though. Did you just end up inverting the levers on the splined shaft so they are pointing down, then cutting them short so the linkage could attach?
 

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Discussion Starter #5 (Edited)
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.

GDI
 

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Discussion Starter #6
I'm attaching a drawing of the brake pedal, and the plate that mounts to the frame. All of the flat steel is 1/4" thick, which is plenty heavy. I've got a 34" inseam, and these forwards feel real comfortable to me (just sitting in the garage so far :frown2:).

Decided to attach a shot of my driveway this morning. It's pretty, but not much of a day for riding motorcycle!

GDI
 

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2014 KLR 650!
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I'm attaching a drawing of the brake pedal, and the plate that mounts to the frame. All of the flat steel is 1/4" thick, which is plenty heavy. I've got a 34" inseam, and these forwards feel real comfortable to me (just sitting in the garage so far :frown2:).

Decided to attach a shot of my driveway this morning. It's pretty, but not much of a day for riding motorcycle!

GDI
VERY nice work. I have as much pollen in my driveway I think.
 

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Discussion Starter #9
I don't envy you for the pollen. I've still got a couple of months before that's a problem here. Spring allergies are the worst for me, though--so not looking forward to that aspect of warmer temperatures. Gotta take the bad w/ the good! :pepper:

GDI
 

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FREEBIRDS MC CENTRAL NY
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sweet
 

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black coffee
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dude those things look great! time in the shop is about all winters good for.
 

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Daily rider
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Nice!
 
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