Savage Project

The Savage project is all about building a bike from scratch, using the all-classic 1 cylinder 650cc Suzuki Savage engine. This big, lazy carburetor driven cylinder allows smooth handling with limited weight and size, and is beautifully classic looking. Being easy on the budget, it was chosen as the preferred horsepower provider for this project.

The challenge started with the design of a fitting frame. We think that the most beautiful bike is a strong and smartly designed bike, which still has maximum elegance. So after sketching all wild frame shape ideas on paper, 2D (Ansys) and 3D (SolidWorks/Cosmos) models were built to check strength and strain under all applicable load scenarios. This analysis was used to further optimize the frame design to ensure a high enough safety factor under all circumstances.

Some upgrades in the frame design after the first calculations, to improve the mechanical stress and strain distribution
Just a quick glance when everything is in place
Design checkin - finding weak locations in the design - focussing on the top tube now. Based on this, the top tube was strengthened.
Finding the largest stresses and strains in the main modes. This has led to multiple tweaks, to reduce the strains and optimize the stress distribution over the frame.
One of the many load cases which were tested
Making a basic decomposition and external forces overview for the first Finite Element Analysis model in Ansys.
Getting the first frequency response of the frame from the basic Ansys model

The design is kept strong, pure and simple – the right lines and angles were sought, to get the right looks while keeping the bike comfortable. Sitting positions were emulated in 3D and tested later on with the first rough frame build. Feel free to download the desktop background pictures!

So, time to start building! Frame material was carried into the TUDelft workshop. Starting with the bare bones: cutting pipes and bending them to the main chassis angels. Preparing nice tube end fits so the welding can be done neatly later on.

Bare bones
Scrapped Savage
Fitting pipes
Checking main angles
Checking main angles

Ok, so making the frame pieces was a nice exercise. Time to start putting everything together and check how it fits. The extra time that was put into exact finishing and of the frame parts paid itself back allright – the tubes fit like a glove!

Well - there's the bare start of the project: the first tubes were put together to form the lower part of the frame. Everything fell smoothly in place at the first try - even the double 3D bends!
Putting the frame parts together
Checking the result after a hard day's work. The frame shapes and dimensions are getting more contour now - this bike is gonna rock!
Checking the result after a hard day's work. The frame's shapes and dimensions are getting more contour now - this bike is gonna rock!
Getting the wishbone position right!
Neatly applying the wishbone tubing
Putting all pieces together here - saddle tube fits nicely - so the frame angles still match the design.
Angles checked, welds applied. Everything matches the drawings - nice!
Trying to nail te exact position for the first welds
The first tubes are put in place for the first welds here

As soon as all main parts were fitted together, the front suspension and wheels were added to check the main aspects of the bike – real life sitting position, ground clearance and such. As a nice bonus the project was used as one of the showcases at the TUDelft. Nice 🙂

A saddle and handlebars would be nice
A saddle and handlebars would be nice
The first chassis assembly was showed here to public at the TUDelft.

After some necessary redesigning, the engine mounts and frame reinforcements were produced. Having all main parts on the shelf, it was time to put everything in place. To assure that all welds are neat and safe, our certified friend Anton the Weldmaster helped us by laying all main structural welds. Better safe than sorry!

The engine is positioned on the lower engine mounts, to tailor all other mounting points
Looks like this thing is not going anywhere.. for now!
Front engine mounts are fully visible, so a nice design is sought.
We've got some nice plans for the front frame plate. Lets first draw our ideas on the rough plate we intend to use..
Time to weld the front engine mounts
Rear enginemounts are put in position. Fits comfortably!
The rear engine mounts are put in place here. Mind the 3d reinforced lower back engine mounts. Solid like a rock.
Rear enginemounts are put in position. Fits comfortably!
All engine mounts are finished. Time for the first engine fitting session!! Luckily, there is enough clearance to actually fit in this huge monster of an engine.
Well, the front frame reinforcement plate and the upper engine mounts are installed here. Looking nice.

Fireworks!
The final welding of the engine mounts. Everything is done the Anton way: nice and slow!
The final welding of the front part. These are important welds because this point gets a lot of stress to endure during its lifetime. Everything is done the Anton way: nice and slow!
The final welding of the front part. These are important welds because this point gets a lot of stress to endure during its lifetime. Everything is done the Anton way: nice and slow!
The final welding of the front part. These are important welds because this point gets a lot of stress to endure during its lifetime. Everything is done the Anton way: nice and slow!
The final welding of the front part. These are important welds because this point gets a lot of stress to endure during its lifetime. Everything is done the Anton way: nice and slow!
The frame is prepared by Anton for welding. Weld areas are cleaned and clearances are checked.

Once the engine has found its place, the tank, front suspension and wheels are put in place to check if everything fits according to the design. This build is only temporary, the frame needs to be painted and many details need to be finalized, but the intended design lines which were optimized on a computer screen, already look even better in real life. That’s a relief 🙂

Well, lots of holes, what else is there to say 🙂
The rear wheel holding plates are put in place and kept at somewhat the right distance using a threaded rod of the same diameter as the rear axle. The plates were point-welded for the moment.
Time to check the shape of the exhaust, to make sure that we leave space where necessary. Like in the 3D-models, we were experimenting with a straight 42mm stainless tube.
The tank, engine and wheels are put in place to see if the overall shape and angles still correspond with our design. We have some space to play around with the tank position.
Here, the carburator is installed with the custom made cilinder inlet. We had to make a custom inlet because the original piece did not let enough room between carburator and upper frame tube. This one fits nice!!
The fuel tank and engine are fitted to find best position for the tank.
Finally, the Harley rear wheel, chain and sprocket have arrived. Nice bling bling chrome, 180 wide. Gives a nice touch!
The while bike with the Harley 180 tire and chain installed. The tire has a good width for this frame, and fits comfortably. The spokes do need some retensioning.

Now lets take a look at all details that need to be worked out. Starting to work on the saddle, brake, front suspension elongation and the exhaust for example. Piece by piece, parts are made and put in place.

The idea is to cut some flames out of the simple bare fender. A simple paper 'mold' does the job.
Pretty nice flames huh! Corners are a bit sharp. We'll see later on if we'll have to adjust them somehow..
How'bout this home made exhaust pipe corner! Small sections cut off under the right angle. Looks cool allright. I don't think i'll paint them, like the way the welding looks on the stainless steel! Nice and conventional.
Here's a picture of the homemade saddle. The stainless steel fits with some other elements on the bike. Still have to polish and tidy up the surface though..
We've elongated the front fork with 120mm to compensate with the large angle. Here you see the results, with the home made stainless covers tightened in place.
Rear brake in position. Probably its designers did not foresee it ill be used this way, but who cares.
Saddle in the making. The two metal plates are put together to check the shape.
Here you see the brake fixing plate, yerked off a XJ600s bike, and somewhat remodelled to fit in exactly. Still lot of work to be done though.
This is what the home made footrests will look like
Here you see the home made foot shifter system, held together by hand. Watch the details at the joints 😉
Next let's try to fit in the self made gear links. The plan is to fit in a hand shifter on the right side of the bike, but for now the footshifter is built in. I'm curious on what feels better.. so why not try both ways 🙂
Hands free 😛

Continuing the build-up, all other details are put in place.

Nice gear shift detail
Saddle
Engine getting refurbished
Brake lever
Building up again!
Good food!

Now everything is fitting together, it is time to get all parts a nice paint job! So.. yeah.. pull everything apart again 🙂

Chassis - first paint layer
Engine getting refurbished
Preparing the paint job
Preparing the paint job
Nice color huh?!

After the nicely done paint job, it’s time to start the final build. Carefully, not to damage any of the freshly painted parts!

Fixing a leakage issue
The bike gets heavier every day!
Som sound and heat protection wrapped around here
After a couple of runs the exhaust starts coloring up nicely

The mechanics are lifeless without proper wiring. So, time to install all necessary components. The Dutch law requires a lot of safety features to get the license plate, so a lot of wiring and components need to be placed.

Time to build in all wiring!
Time to build in all wiring!
Gotta keep things organized. Takes lots of coffee.
Yeah, then there was LIGHT!

So this is it! Everything is installed, everything works. The first test ride is driven, the bike drives beautifully, handles easily and sounds nice and rough! Although there are some concerns about the sound levels, we ship off to RDW for the final technical checkup. Here all required features and functionalities are checked, before a license plate is issued. On a separate test track, the bike’s brakes are tested, handling is tested and sound level measurements are carried out. Also, this is actually the first time that the bike is driven this much 🙂 Test results: everything ok except one test result: the sound level is too high. We’ll have to fix that and return for a second test!

Shiny details
Proud team
Filling up!
Proud boss 🙂
All set up. Ready to go.
On the way for the technical RDW check. Cold outside.

So after installing some top-secret, self made sound level killing features, the bike is ready for the second RDW check up!

And guess what: PASSED!

Getting hot?
Need some more sound muffling, so an extra sound damper was built.
Extra sound damper placed
Bike got through its technical exam, RDW grants the permit to put a license plate on it! YEAH project finished!!! What a ride!

This brings us almost to the end of this project. Some optical tweaks will be carried out after the license plate is put place, but for now, we’ve done it!

Proud to be part of this team 🙂

~ Gabriel ~