OK, here we go.
I got both footpeg lowering brackets built and mounted.
I actually started over this morning and threw away the work I already did on this. I started with a 3ft length of 1"x1"x1/8" steel angle. I cut the brackets down using a miter saw with an abrasive metal cutting blade, which worked pretty well and was way faster and cleaner than using the angle grinder. Then I did some shaping using my bench grinder.
Next up I drilled the holes to mount them. Basically each side has two pieces that bolt together, then this all bolts to the bike. I tapped the holes where the original "rearset" mounts with an M8 tap so I can use the original bolt.
Right side all mounted up. Still have to figure out how to attach the rear brake MC and brake light switch but I have ideas.
Things get more interesting on the left side due to the shifter.
Bracket mounted:
Test fitting the peg assy:
Now, I needed a way to mount the shifter. Originally I was going to just attach it to the "rearset" plate just ahead of the foot peg but the peg would interfere with the linkage if I did that, so I needed to mount it higher than the peg. I made up a little aluminum plate and bolted it to the peg mounting plate, and then drilled a hole, tapped to M8 and mounted a bicycle cantilever brake post to it. The shifter will ride on the brake post.
Then I chopped off the original shifter to make a linkage part, and drilled a hole, tapped with M6. Put on a M6 heim joint for the linkage. Mounted up the shifter, and here it is test fit:
I still need to get a M6 threaded rod or screw I can cut off that's about 110-115mm long, then the left side will be good to go.
Still remaining is working out the rear brake MC mounting and brake light switch mounting, which should be easy enough. I will need a longer brake reservoir hose and lengthen the wire running to the brake light switch. No sweat. I just got tired of working on it today.
The issues are about the left side. The center stand is probably going to have to go. With the peg in this position, my heel presses down on the center stand foot pedal. The bigger problem is the side stand, which basically when raised runs right into the bottom of my extended peg assembly. I don't think it's likely that it will fall down on its own so it may really not matter that much, but it wouldn't hurt to have a dogleg-shaped side stand and I need one an inch longer anyway. So I might see if my dad wants to fire up the welder and maybe we fab something up.
In this position the pegs are about 1.5" or so forward from the stock position and most importantly about 4" lower. They are also 1" further out from the centerline of the bike. It's WAY more comfortable for me, and this accomplishes the goal of making pegs that I can stand on, which is part of the "adventurizing" of this bike.
It looks a bit Mad Max right now but once I get everything fabbed up I'll take it back off and sand and paint it to match the frame and my guess is it won't look so nutty. Probably will repaint the whole original rearset plates as well. Remember I raised the rear of the bike about 1.5" or so by virtue of the Katana600 shock, and the front is raised about 3/4" in the triples, so I am not worried about ground clearance or cornering clearance. Also I am using my knock-off handlebar "risers" to set the bars back about 2" from their stock position, since it's quite a reach across that long tank if you adjust the riding position to be more upright. Sitting on the bike with the KX-bend handlebars sitting 2" back from stock and the low-forward pegs, it really does have a similar position to an adventure-type bike, maybe a long version of a dual sport bike.
I'm actually very anxious to get it back together and go ride it. I rode yesterday on the Triumph and again got kind of beat up on some rough roads. There are a TON of these dodgy Texas county roads with occasional gravel sections and extremely poor pavement conditions and the GS with the current suspension just floats over this while the Triumph is punishing. Actually I think my slightly modified GS will be a pretty decent adventure type bike.
For whatever reason it's been raining most of the time in CenTX since August last year, particularly on the weekends. So that means I have plenty of time tomorrow to figure out the rear brake stuff. I'll probably have to wait for Monday to go to Fastenal to get a long M6 bolt to make the shift linkage complete. Then I'll have to wait for it to not be raining to paint all this, but I'm going to wait until after I can ride it some to paint it.
