Joe....
Understand that the following, as with pretty much everything I try to help out with on this site, is my opinion.
Saying that will possibly open up for more conversation.
I'm curious where you are going to purchase a complete OEM ignition switch from? Only ones I know of are being hoarded by owners. Jamie/Marty have none, and have not for quite a few years now.
Every single OEM ignition switch is going to self destruct. EVERYONE. I've seen one where it was taken out of the factory box, and break behind the butterfly/thumb tab fresh out of the box.
With close examination, the design appears to have been a possible last minute concept... Butterfly/lock cylinder is made out of pot metal, and over 2/3 of the way thru the cylinder, is a factory cut, for the detente stop on the switch. It breaks at that cut 99% of the time.
The piece gorgeous to look at, but not durable.
2 years ago, my switch grenaded (at about 32k miles). I had parts from several other salvaged switches, and sent to Jamie for the Stavos upgrade. At that time Jamie told me that the Stavos he installed on my switch was the last one he was going to do, as he had no more parts and "we've never made any money on the Stavos, due to all the phone calls with owners"....
With that, I know of no one currently installing the Stavos upgrade on the switches.
At the Minnesota 20th, I saw a couple of Jamie/Martys own designed upgrade. And to be honest I was surprised. It looked great, and as usual quality was of the top order. But keep in mind, that there are no more butterfly/thumb tabs out there, so their design has that piece missing.... still looks good though.
Since my installation of the Stavos, a few things have happened .... with the switch in general within the community.
Mike Degroot, came up with a HD parts installed on our housing, that also looks very nice. I'm sure a few other owners have also come up with some design that work well, and are pleasing to the eye.
When Jamie told me that he wasn't going to do the Stamos anymore,.... I and a buddy got together and came up with what we call the Footsky. (I know silly name, but its a combo of our last names and everyone will know which design it is). Our design requires an all original complete switch (unbroken). We feel out design will prevent, if not eliminate grenading of the switch. We are not building these, but I will be more than happy to send pictures and explanations of how to do the footsky. Its really not to tough, and if you have a friendly machinist..... cost would be under 100$ easy. Just ask, I'll send with pictures. wytfut@windstream.net
Also during this period, I got a few guys together, that all appreciate the Excelsior Henderson line of bikes... and with some technical work, came up with a "file" design for 3D printing the butterfly/lockcylinder piece (the piece that 99% of the time breaks). This project was zooming along nicely, and then came to a screeching halt when I couldn't get anyone to chrome plate our piece. Plastic chrome is not uncommon, (in fact its pretty common) but everyone I contacted was looking for a large batch to be made. Something I couldn't afford. Its a perfect match to be honest. My goal on this piece was to build this for around 100$ including chrome, and up til then it was right in the ball park.
My next step, I contacted Dan Hanlon.... as I was frustrated, with no motion forward. Dan was thrilled as it had been a personal goal of his to pursue this issue also.
Dan wants to CNC this piece, and currently the project is in his hands. Hopefully he wont have to start from scratch and can have the 3D file converted to CNC file. So there is an answer out there, currently.... time will get us what we need.
Another unknown issue with our butterfly/lockset, is finding an manufacturer/source of the actual lock. I'd guess most grenaded switches the lock remains intact. But I know for a fact, many have disappeared in the twilight zone of the road shoulder.
So Joe and anyone else reading along... is the long story on everything I know about our OEM switches and choices:
Install a brand new one and never ever ride it (and it still may break).
Find someone to resurrect the Stavos update
Build your own switch and preserve your OEM switch on a shelf (and it still may break)
buy Jamie/Martys design upgrade switch
contact Mike Degroot about his design (or anyone else that has some end result)
contact Bruce for info on the footsky
park your X and wait until the new product is completed
I know this probably sounds a bit bitter and bleak.... I don't mean it to sound that way. In fact quite to the contrary. We as a community have overcome some huge obstacles. All of us old timers that have been in this game since the beginning have seen all of the issues solved. This is just another one, and it will be solved. Ride your X, enjoy it. Switch breaks... find something you are happy with so you can ride it more, until the next generation of switches come out.
I suspect (plus others) that with all the milage our Xs are piling on (I'm at 44k miles now), new issues are bound to pop up besides ignition switches.
Good riding Joe!!
Bruce
flatlandersupportingXworld
