internal wiring for stock handlebars
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Intermediate
Joined: Feb 2008
Posts: 39
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From:
internal wiring for stock handlebars
Hey guys,
I have seen it done and was interested in doing it myself, but thought I would ask here first to see if anyone else has taken on this endevour.
Thanks,
Guns
I have seen it done and was interested in doing it myself, but thought I would ask here first to see if anyone else has taken on this endevour.
Thanks,
Guns
Outstanding HDF Member
Joined: Dec 2007
Posts: 2,215
Likes: 2
From: Northern Arizona
RE: internal wiring for stock handlebars
I know must be careful on the drilling as could weaken the bars at the most inopportune place, which could cause them to snap at the most inopportune time.
Elite HDF Member
Joined: Aug 2007
Posts: 4,265
Likes: 99
From: Northern VA
RE: internal wiring for stock handlebars
If it were me, I would look into after-market bars that were dimpled and drilled... Drilling out your bars gives rust a nice place to start. Aftermarket bars are drilled then chromed...
RE: internal wiring for stock handlebars
dude bars are mad strong... unless you drill a huge hole you are fine, i have done it.... someone on here has a step by step how to intrenal wire your bars i belive it is in the tech part of the forum... if you can not track it down let me know and i will write you up a step by step, I learned alot doing mine and could do it much faster now but i solder alot, many people do not like to do that... i am good at it and do it all the time so i do not mind it, if you like to solder and oyu are good at it you can just:
- Cut them below the tripple tree
- solder in extensions about 12 in a piece (i did at least)
- mark your bars while they are on the bike where you want to drill
- drill bars
- make the drill hole super smooth! file it sand it do what ever but make it so it is smooth! you should be able to pull a cotton ball though that hole without it getting caught up is how it was put to me.... put some of your girls clear nail polish on that hole to keep it from ever rusting... rust problem solved...
- take fishing line and blow it from the middle hole to each hole in the grip part....
- tie the fishing line to the wires and pull them though (i shirnk wrapped them super tight)
- solder on to the other ends of the lines
- granted do not forget to use shrink wrap and the wire wrap and zip ties and all that fun stuff, by taking your time and really doing this right it will save you!a wire shorting out can leave you stranded on the side of the road! take you time, do it right... you will be cool... plus it looks sick!
if you need a hand there is plenty of help on here!
[IMG]local://upfiles/26534/BED84FF0FA0F4B8CAB51014F9C77BD8E.jpg[/IMG]
- Cut them below the tripple tree
- solder in extensions about 12 in a piece (i did at least)
- mark your bars while they are on the bike where you want to drill
- drill bars
- make the drill hole super smooth! file it sand it do what ever but make it so it is smooth! you should be able to pull a cotton ball though that hole without it getting caught up is how it was put to me.... put some of your girls clear nail polish on that hole to keep it from ever rusting... rust problem solved...
- take fishing line and blow it from the middle hole to each hole in the grip part....
- tie the fishing line to the wires and pull them though (i shirnk wrapped them super tight)
- solder on to the other ends of the lines
- granted do not forget to use shrink wrap and the wire wrap and zip ties and all that fun stuff, by taking your time and really doing this right it will save you!a wire shorting out can leave you stranded on the side of the road! take you time, do it right... you will be cool... plus it looks sick!
if you need a hand there is plenty of help on here!
[IMG]local://upfiles/26534/BED84FF0FA0F4B8CAB51014F9C77BD8E.jpg[/IMG]
Road Master
Joined: May 2007
Posts: 883
Likes: 0
From:
RE: internal wiring for stock handlebars
i just started to do mine. i drilled the holes yesterday and got a pull wire through. im going to try and get them mounted over the weekend. my only concern is getting the at the connector. hope i dont have to remove the tank. if i do ill wait for a little warmer weather because id have to drain it
Outstanding HDF Member
Joined: Jan 2007
Posts: 3,438
Likes: 3
From: Chesterfield, VA
RE: internal wiring for stock handlebars
ORIGINAL: bikerdog134
i just started to do mine. i drilled the holes yesterday and got a pull wire through. im going to try and get them mounted over the weekend. my only concern is getting the at the connector. hope i dont have to remove the tank. if i do ill wait for a little warmer weather because id have to drain it
i just started to do mine. i drilled the holes yesterday and got a pull wire through. im going to try and get them mounted over the weekend. my only concern is getting the at the connector. hope i dont have to remove the tank. if i do ill wait for a little warmer weather because id have to drain it
[IMG]local://upfiles/23085/F304FE724A9044688EA024A26608C980.jpg[/IMG]
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Cruiser
Joined: Dec 2007
Posts: 114
Likes: 0
From: Missouri/working in Kuwait
RE: internal wiring for stock handlebars
Correct me if I am wrong but I believe new HD bars are made of stainless steel.
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Road Master
Joined: May 2007
Posts: 883
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From:
RE: internal wiring for stock handlebars
thanks for the feedback. i cant wait to go at it. its suspposed to be in the thirtys over the weekend. that sounds pretty simple. thanks again. as far as being stainless, i have changed them. the original were but the ones i have on our not. i already have them drilled. thanks again
Outstanding HDF Member
Joined: Dec 2007
Posts: 2,215
Likes: 2
From: Northern Arizona
RE: internal wiring for stock handlebars
[- take fishing line and blow it from the middle hole to each hole in the grip part....
- tie the fishing line to the wires and pull them though (i shirnk wrapped them super tight)
Even better, using electrical tape, wrap a long piece of stiff safety/mechanic's wire around the wire bundle with a couple inches of overlap, push the stiff wire down from the grip holes and out the center hole and pull through. Took me all of 1 minute per side to feed the wires back through.
- tie the fishing line to the wires and pull them though (i shirnk wrapped them super tight)
Even better, using electrical tape, wrap a long piece of stiff safety/mechanic's wire around the wire bundle with a couple inches of overlap, push the stiff wire down from the grip holes and out the center hole and pull through. Took me all of 1 minute per side to feed the wires back through.