Here is a quick paper on the MadDad Modification to the Intruder 1400's rear end.
We will do a better version, soon. I needed to get this up quick for Ron.






I have attached another small pic. of the brass fitting's birth. 1. The left object is a 1/2" pipe to 3/8" OD copper tubing fitting. What's nice about this part is the inside diameter of the hole is just the right size for a 5/16' tap, course or fine. The Visor lights come with a 5/16" hollow bolt for the wiring. It would be easy to drill out to a 5/16" hole needed for a 3/8" bolt tap. 2. The second picture has the small end cut off and tapped the brass piece to 5/16" NF. 3. The third pic. is the fitting turned down to @ .62" which fits in the frame hole on the bike. Now I don't have a metal lathe. I chucked a spare bolt with the head cut off, and the brass piece threaded onto that, in a drill press then with files, course then fine, "turned" it to size. It didn't take but about 10 min. 4. I tried several options, and the forth object is one I rejected. It is the right length @ .56" with a 6 mm tapped hole for the screw that holds it in place. I tried turning the piece to @ .55" in dia., and filing groves to hold some O rings for shock absorption, but it was a pain to get everything the right sizes. May try again this winter. I ended up turning a piece @ .56" long and of a diameter, @ .58" that which combined with a single layer of thick electrician's splicing tape for vibration absorption came out to .62", with a spot cut out for the screw that holds it in place. 6. I screwed the hollow bolt onto the brass piece, then the light onto the bolt that was sticking out. I then held this in place and marked where the 6 mm screw would go onto the brass piece with a Sharpie. Drilled and tapped that hole in the brass. Put it all back together with locktite and screwed it down. Did have to grind off about 1/8" of the 6 mm screw as it was hitting the 5/16 in bolt and not snugging down the brass piece. 7. Again I had to take out the rubber grommet that is in the fender hole to make enough depth to allow for the bolt head. I thought about cutting off the bolt head and just using the hollow threaded part, along with some set screws, but time was my first consideration. The wife wanted to go for a ride, not watch me sweat in the garage.