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I took a set of HD Legend BigFoot Forward controls Controls ( forward_controlsFIVE.asp ) and modified them.  One can now buy adaptors to fit the controls to the RoadStar or buy some Legend FCs that fit the RoadStar.  Rather than making an adaptor for the controls, I chose to make new mounting plates.  I first made mockups out of wood in order to determine the best riding position for me.  For the final plates, I used 1/2" alumnium T6006 and cut it to shape with a jig saw.  I then used a milling tip to shape and smooth the edges and drilled the appropriate holes.  I also made 0.5" spacers to place between the FCs and the frame in order to set them out from a bit a bit.  I'm going to make a set of 0.75" and 1" and see how it feels.  I sanded and polished the plates and if I'm satisfied I'll have them chromed next year.



  


Removing the hardware from the original backing plates on the shifter side was a bitch.  I used my bench vise and rubber mallets to persuasively, but gently, pry them off.  I moved the pivot point for the shifter lower down so that not so much empty plate was visible.  

To hook up the brakes I used a 3/8-24 I F Male x #3 Male 150 degree bend adaptor at the master cylinder.  I gently bent the adaptor a little more so that it would be closer to the back of the FC.  From the adaptor I used 28" braider brake line which is hooked up to the HD brake tee switch (1/8" NPT x 2 - #3 male ends) that you can see below.  The switch sandwiches perfectly between the two original brake hose nibs on the frame and is held there securely.  I took the original brake switch wiring, re-routed it back and spliced some extra footage on it.  From the switch to the rear caliper I used an 18" braided line. looped and held in place on the frame by the original bracket.

I had to also fabricate a new shifter arm.  For the time being I took a 1/2" aluminium rod and cut it to a length of 15.5".  This size results in the shifter lever being at the same angle as the frame without too much thread being visible on the adjusting bolts.  The front end of the rod I drilled and threaded to 3/8", as the ball joint end on the shift lever is fro HD.  A piece of 3/8' stainless steel rod connects the ball joint end to the shifter rod.  At the transmission side I drilled and threaded for the stock ball joint.

Overall .... I like the forward controls better the original floorboards.  The extra heel pad gives me a little more space to move my feet around.  The bike is not lowered and I still scrape the pads on turns!  I have to find something to add on the bottom of the pads to 'adsorb' the wear.

 

PROBLEMS:  The bolt holding the right side peg is a normal thread, rather than left hand.  When I apply any kind of pressure to the heel rest part of the peg, it twists the peg loose.  In contrast the shifter is OK because as you press down on the heel rest it tightens the peg.  To date I've tried torqueing the bolt down and inserting a toothed washer between the peg and mounting plate but it doesn't work.  I have now put some red Loctite I'll soon see how that works.

The link between the heel rest and the peg is exactly where I rest my heel most of the time.  This part should have some black rubber material on it as it is quickly becoming scuffed.