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October 4, 2024, the last few Commandos I've worked on had issues with the mounting
of the master switch. Often, the issue is that stock air filter was removed, and
with it, the mounting point for this component. In each case, they had a cobbled
together solution
that was far from ideal.
I set out to resolve this issue with a bracket that would securely mount the master
switch in various locations and orientations. I designed the bracket and sent the
design to a CNC shop to have 10 prototypes made. They came out perfectly, but cost
me quite a bit each. The first three pictures show the brackets from various angles.
The next four pictures show some optional mounting locations. Since this is a customer
bike I'm working on and one that needs the bracket, I am not drilling any mounting
holes for these pictures, just using a clamp to show how the bracket could be installed:
- The first is the simplest. It just screws to the battery tray where the rear plate
of the "hamcan" air filter would mount. This could be more towards the center of
the bike if desired using other mounting holes in the bracket. This is probably
the least useful mounting location as it will not work for MK3 or others with the
cNw e-start. It would also have the wiring in a weird location. The other options
do work with the MK3 or cNw equipped bikes.
- The second is much better. The wiring would be much more natural, and the switch
is tucked in close to the frame tube. It is lower than standard and requires drilling
two holes in the front of the battery box. Again, it could be located closer to
the center of the bike if desired.
- The third shows the switch higher which is closer to standard. Again, the wring
would be a little exposed and again the bracket can be shortened to move it even
a little higher and towards the center of the bike.
- The fourth is my favorite as long as you have a reasonable sized battery. In this
one you drill two holes in the bottom of the battery box and shorten the bracket
if desired. It is shown full length.
There are several other mounting methods possible, and the bracket could be bent
to add even more.
These brackets are made from 1008/1018 Cold Roll Steel, 0.093" thick in New
Jersey, USA. As shown is how they arrived today. The edges are sharp, and they have
some surface rust and minor tooling marks. If sand blasted the sharpness goes away
along with the surface
rust. When I use them, I will powder coat them black.
If there is enough interest, I will have a production run made which will make them
inexpensive.
If you have any questions, call or write.
The first three pictures show the bare bracket in different views
The next four show various mounting methods will work with all but Interstate side
covers.
The last three show an option for a pre-MKIII Interstate with a cNw starter and
single Mikuni carb. There is clearance to all components. The bracket the bike had
was nightmare. To change the air cleaner, you had to unwire and remove the battery,
remove the switch from the bracket, and remove the bracket! Even worse was that
with that bracket and the original master switch wiring breakout from the harness,
the master switch wires were forced to lay on the air cleaner which caused wire
and air cleaner damage - hence the re-wiring in progress.
The bend doesn't look great because I had a brain fart - I bent it perfectly
in the wrong direction. It looked great but clearly would not work. So I bent it
the correct way but that was no longer a smooth bend. I have a very limited supply
of them so I didn't want to start over.
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