WTH?!?!? I never received a notification of replys to this post...I thought there was no interest! I finished the pegs, and they are really great! I made a new post over on ADV Rider, I'll copy it here.
After much googling and not finding a suitable passenger footpeg upgrade I decided to make my own.
My first thought was to just remake the whole peg, but that would take a ton more programming time, and I would have to use the 4th axis. This was a project I was hoping to squeeze in between other jobs, and the 4th only goes on the machine every few months, and I didn't want to wait.
So I started by taking off the rubber insert. There are a couple screws that go up from the bottom into the rubber insert, pretty simple. Maybe I can just make a wider insert then thread in from the bottom in the same manner as the factory.... But the screws are pretty small (M5 if I had to guess, but I didn't measure), and they are just Phillips (more likely JIS). After much measuring and head scratching I figured I could get an M8 screw through the top if I opened the holes up just a little bit in the peg. Then throw a couple nuts on the bottom and sandwich the new peg onto the old one.
That was the original plan, and this was the model I came up with.
I made the counterbores extra large because I wanted to use a washer in there to help spread the load. I didn't end up doing that. There really isn't room on the bottom for nuts, and I didn't want to mill out the bottom of the pegs to make room...this was supposed to be a quick project! Of course in my haste, I didn't realize that until after the left side was out of the machine...The big counterbores stay.
Who doesn't like a little bling?
Mirrored set...
I just bored out the stock footpegs with a larger drill (letter I drill) and tapped the peg with an M8x1. This way if the wifey doesn't like the pegs I can still put the stock rubber ones back on. and the only change from stock is about .030" more clearance in the holes.
Folded the left side 'just' makes contact. I'm not too concerned.
If I was to do it again, I would make the counterbores smaller. I think it looks silly like that. I would also make the 'knurling' sharper. These aren't off-road pegs (I'm bad enough in the dirt on a smaller bike...this pig and a pillion, no thanks!), so it shouldn't really matter, but I'm anal like that.
I have about 5 hours total in this project, and that includes programming and chopping down a much larger piece of aluminum because we didn't have any 5/8 barstock at the shop.
After 1400 miles this weekend, and about 50 before that, she can't be happier with them. The blue is starting to wear, and the black oxide is starting to show rust. But the blue was just Dykem Marker that I stoned off to leave the paint inside the engraving. I never thought it would last long. I'll look into some stainless bolts to fix the rusting. Plus I think stainless would look better anyway. I may just re-make them anyway to fix the other issues I have with them. But I'm lazy, so that won't be any time soon!
