Welding steel to stock shift lever : V-Twin Forum: Harley Davidson Forums

jonny oz · 01-24-2013, 10:36 AM

Good day, All,
I have a plan to essentially cut off the pad portion of my brake lever, and tap a hole for a peg (to match the shift peg).
Then I want to make a shift lever out of flat steel so it (hopefully) matches the brake pedal lever more than the stock shift lever. I'm thinking I'd take just the splined bottom part of the stock lever, then weld the new one to that. Then it's all getting black paint.
I can't think of any other way to attach the new shift lever to the splined shaft. I've searched the aftermarket and don't like the options, and would rather have a 1 off setup anyways.
Now the question: does anyone know if the stock shift lever is cast, and will it be ok to weld mild steel to it? Don't worry I'll prep it right.

Any additional ideas are welcome

Thanks!

RogerDodger · 01-24-2013, 11:15 AM

It'll be OK to try - many have. And many have failed.
Take your aluminum lever to a machine shop and have them machine a steel copy of the splined portion that you can weld your flat steel shift lever to.

Danglide · 01-24-2013, 12:00 PM

if you're going to the trouble to make your own lever,why not powdercoat it? get a durable finish that way.

jonny oz · 01-24-2013, 01:15 PM

Aluminum huh? Won't be trying to weld that, thought it would be steel. I'll call some machine shops, thanks.

I thought of powder coat, might look into it, but I've used a black brake caliper paint in the past on other parts that you bake on in an oven, and it's really durable, gas proof, less than $10/can, that's what i was planning on.

Danglide · 01-24-2013, 01:18 PM

Quote:

Originally Posted by jonny oz

Aluminum huh? Won't be trying to weld that, thought it would be steel. I'll call some machine shops, thanks.

I thought of powder coat, might look into it, but I've used a black brake caliper paint in the past on other parts that you bake on in an oven, and it's really durable, gas proof, less than $10/can, that's what i was planning on.

do you have a link to that paint? I've been planning to powdercoat a lot of things on my bike,but not looking forward to the downtime or the expense.A durable baked paint might be just the ticket for some items.

BigPeet · 01-24-2013, 02:31 PM

Quote:

Originally Posted by RogerDodger

It'll be OK to try - many have. And many have failed.
Take your aluminum lever to a machine shop and have them machine a steel copy of the splined portion that you can weld your flat steel shift lever to.

None of my levers are aluminum.

If you are going to have to take it to a machine shop you'll end up with an expensive lever.

~Pete

Nitram_b4 · 01-24-2013, 04:36 PM

cutting internal splines on a one off would be expensive

jonny oz · 01-25-2013, 11:03 AM

http://www.vhtpaint.com/products/caliperpaint/

That's the link to the VHT site for this paint. I got mine at Canadian Tire, I know that doesn't help you Americans but I'd assume they'd carry it at any big auto parts store. I have it on my exhaust mounts and tank...paint job is about 4 yrs old, still looks good.

I called a couple machine shops, sounds like just a splined hole in a chunk of steel will run $300 and up...no thanks. I'm just going to try sticking a magnet to the shift lever, that'll tell me pretty quick if it's aluminum.

RogerDodger · 01-25-2013, 11:59 AM

Dude, it's either aluminum or pot metal (Big Peet must not own a Harley). Either way you're screwed as far as the welding thing goes.
One-off customizing can be spendy, particularly if you don't do your own machining or have a bud that does.

BigPeet · 01-25-2013, 02:11 PM

Quote:

Originally Posted by RogerDodger

Dude, it's either aluminum or pot metal (Big Peet must not own a Harley). Either way you're screwed as far as the welding thing goes.
One-off customizing can be spendy, particularly if you don't do your own machining or have a bud that does.

RodgerDodger, It's always a good idea to know what you are talking about before posting. It can save the OP a little more time with his project.

I would think you would at least go put a magnet on your lever after my post questioning your aluminum lever.

But if it was aluminum, which it's not, why would you say you can't weld it?

And yes I have a FXR and a Road King. Both with steel levers.

~Pete

Harley Cruiser · 01-25-2013, 06:07 PM

It is steel, remove the chrome, weld away, use stainless if you want to polish it later.
Better yet why not just cut off the old lever and leave a inch or so and then just bolt the new one to it.

CHIPMAKER · 01-25-2013, 06:17 PM

Did anyone notice the join date (2001) and post count (2) ?????

thefour · 01-25-2013, 09:00 PM

Quote:

Originally Posted by CHIPMAKER

Did anyone notice the join date (2001) and post count (2) ?????

At a loss why that matters.

Harley Cruiser · 01-25-2013, 11:24 PM

Quote:

Originally Posted by CHIPMAKER

Did anyone notice the join date (2001) and post count (2) ?????

I joined a long long time ago, used to post a lot, don't know why it just says two post, guess I don't get credit if I am not a regular;-)

jonny oz · 01-25-2013, 11:30 PM

...getting back on track...
magnets stick to the shift lever so I'm assuming it's cast steel. I've checked a few welding forums and by the sounds of it, cast steel MIG welds fine. There's not much stress on the shift lever so I'm not too worried. I did buy an extra shift lever off ebay just in case.

It's been -30 Celsius here this week and my detached garage isn't heated, so if we get some nice weather I'll get at it. If it goes well I'll post some pics.