DIY Internal wiring
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Tourer
Joined: Oct 2006
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DIY Internal wiring
Anybody got any instructions or good advice on drilling stock bars and pushing the wires internal?
I just bought a set of 12 in apes and Im putting them on my LowRider. Im sure several of you have gone through this and Im hoping I can gain from your advice. Ive done internal wires a couple of times but never drilled the bars. Where do you drill, how big, and how hard is it? The bars I have are dimpled but no holes....
I just bought a set of 12 in apes and Im putting them on my LowRider. Im sure several of you have gone through this and Im hoping I can gain from your advice. Ive done internal wires a couple of times but never drilled the bars. Where do you drill, how big, and how hard is it? The bars I have are dimpled but no holes....
RE: DIY Internal wiring
i just did that on my black mini apes and to start with i covered them in masking tape so i wouldn't scratch, drilled the end of thedimples pointing the drill toward the inside of the bars(not sure of the size of bit but i drilled small pilot hole then sized up a larger bit with wire harness), two holes side by sideon bottom/middle of bars, connect holes with cut off wheel on Dremel (need a fairly large hole to get all the connector pins through) then grind and fileall sharp edges. blow a string through and connect wires at grip end and pull/push through down to bottom. no need to disconnect wires from grips. a little grease helps it slide through a little easier
Road Master
Joined: May 2006
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RE: DIY Internal wiring
As Jay mentioned about drilling your bars I'll take it a step futher. I just did mine last month and put them in my shop vise between 2 wood blocks. I didn't tape them up, just started with small
pilot holes and increased them to 3/8" at the grips and did the same as Jay with 2 connected 3/8" holes at the bottom of the bars connected using a dremmel tool.
You defininitly want to file all the holes very well. I tied a 1/4x20 nut to some mason line and just shook it trough the bars. Wire lube will help get the wiring harnesses through the bars but liquid
hand soap will work in a pinch. You may want to buy some good (3M super 33) electrical tape and tightly wrap the wires. Draining and taking off the tank will make it alot easier to get to the
control wiring inside the frame. You may also want to get the service manual for your bike as it details how to take apart the various wir connectors.
Do a search as there are many threads about wiring bars.
Good luck.
pilot holes and increased them to 3/8" at the grips and did the same as Jay with 2 connected 3/8" holes at the bottom of the bars connected using a dremmel tool.
You defininitly want to file all the holes very well. I tied a 1/4x20 nut to some mason line and just shook it trough the bars. Wire lube will help get the wiring harnesses through the bars but liquid
hand soap will work in a pinch. You may want to buy some good (3M super 33) electrical tape and tightly wrap the wires. Draining and taking off the tank will make it alot easier to get to the
control wiring inside the frame. You may also want to get the service manual for your bike as it details how to take apart the various wir connectors.
Do a search as there are many threads about wiring bars.
Good luck.
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