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Forward controls

PostPosted: Sat Jun 12, 2010 4:15 am
by Blindstitch2002
Created by Natrik

Sooooooo... I finally did it. I've got my sanity back, and here are some pics. I was really lousy about taking good pics with this one, and I kept changing things to make it work so it was hard to keep up with myself.

I used Charles' design, so I'm going to save some time and tell you to look at his page on forward controls. I had to make mine a little different, though, because I still have my H-box and heat shield. Just two extra bends in the arm I used for the shifter. I loaded up on old sport bike shifter parts from Cyclepsycho. I think I used five of those ball joints on the shifter side alone. I tried an idea to use less joints but it didn't work at all.

Charles said it took him several months of trial and error, and it took me well over a month to copy his design. This is by far the trickiest fabrication project I've taken on. Very frustrating.

Anyhow, look at the pics and ask me questions. Hopefully I can make it easier for the next fellow who tries it....

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I cut off the ends of my highway bars (see the "Highyway bars" thread), welded bolts to heavy washers, then welded the washers to the bar ends.

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I screwed on sport bike pegs with shafts that allowed the shifter and brake pedals to pivot.

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Mock-up of shifter parts.

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Parts welded together.

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Lousy close up of the shifter arm. Charles has a better one of his.

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After my first test ride I decided to make it a heel-toe shifter. It is a little stiffer than the stock shifter and I didn't want a bruise on my big toe (I'm a real badass, can you tell? )

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Modified brake pedal

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Final parts painted.

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Finished shifter.

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Finished brake.

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Entire shifter.

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Entire brake.

So that's it for now. I'm going to re-do the brake inkage and make it from hollow tubing like Charles', mine flexes a little and I can't get full braking power out of it. The shifter works great.
After doing this, I realize why those two German websites want $500 and $600+ for their setups. Almost worth it if you had the means......

Re: Forward controls

PostPosted: Tue Oct 12, 2010 12:07 am
by jamesferra
do you have a parts list of everything you got. you and charles have a great idea going on here. i have told some people i know about this place and choopercharles. so you just cut the highway bars that you had and used that as your down tube im guessing

Re: Forward controls

PostPosted: Wed Oct 13, 2010 10:11 am
by Gman
We don't get that busy on here.The Customization sections of Chopper Charles should have some answers for you,

http://cx500forum.com/index.php?/forum/ ... 2f6008e23b

:)