drilling bars for internal wiring...
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Ultimate HDF Member
Joined: Oct 2007
Posts: 7,562
Likes: 11
From: Palm Harbor fl.
drilling bars for internal wiring...
started on it but the bars are too strong for my drill bits... what size holes are needed and what drill bit should I use to slice through these bars?
I use step bits... each hole i drill i match to the size of the wire that needs to go though it (after it is bundled and shrink wrapped tight) then i use a step bit to get the size perfect (harbor freight has a decent set for pretty cheap) put the bars on the bike and mark them where you will want, the insert holes by your controls and the outlet hole as well... after you get those drill a small pilot hole... rounder it is SO SO SO important that you propperly wrap your wires, as well as make sure the holes are completely deburred, i was told long ago, you should be able to pull a cotton ball though the hole without it catchin at all (this is also how i test my holes, no joke) ... if not that sharp edge could leave you on the side of the road wiht a short.... i electrical wrap the wires then shring wrap them... may seem like over kill but i would rather the piece of mind for me as well as my customers
step bit:
step bit:
Road Master
Joined: Feb 2008
Posts: 1,214
Likes: 0
From: Tacoma, WA
I have use a step bit like JRK and then a Dremmel to do a couple sets of bars. I drill out two holes about inch and half apart and then use the Dremmel to connect the holes. Once I have my openings I use a small grinding bit on the Dremmel to remove burs and smooth out the edge of the cut.
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Ultimate HDF Member
Joined: Oct 2007
Posts: 7,562
Likes: 11
From: Palm Harbor fl.
ah... never seen those... will get at sears tomorrow... yeah I am an over kill guy when it comes to wiring too... shrink wrap... over wrap with electrical tape...I figured I would drill out two large holes(7/16-1/4") in the bottom then ovalize them together into one hole with the dremmel...
I started small and went bigger and bigger with the bits, but , my larger bits don't seem to want to cut through the bars.
those made of carbide?
I started small and went bigger and bigger with the bits, but , my larger bits don't seem to want to cut through the bars.
those made of carbide?
Thread Starter
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Ultimate HDF Member
Joined: Oct 2007
Posts: 7,562
Likes: 11
From: Palm Harbor fl.
I have use a step bit like JRK and then a Dremmel to do a couple sets of bars. I drill out two holes about inch and half apart and then use the Dremmel to connect the holes. Once I have my openings I use a small grinding bit on the Dremmel to remove burs and smooth out the edge of the cut.
Road Master
Joined: Feb 2008
Posts: 1,214
Likes: 0
From: Tacoma, WA
I put an oval in the dimple at the switches. I also shrink wrap the wires in the bars and the larger hole makes it easier to get the bundle of wire out at the switches.
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Road Captain
Joined: Jun 2007
Posts: 662
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From: SE Michigan
Ok you guys got me going.
Can you bury all the wires, even the turn signals in the stock bars?
Do you pull the wires loose from the switches then pull them up thru the bars and back out again? Your not cutting the wires.
Is there a how to posted on this?
Can you bury all the wires, even the turn signals in the stock bars?
Do you pull the wires loose from the switches then pull them up thru the bars and back out again? Your not cutting the wires.
Is there a how to posted on this?
Thread Starter
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Ultimate HDF Member
Joined: Oct 2007
Posts: 7,562
Likes: 11
From: Palm Harbor fl.
this is drilling a "stock" bar.. the wires get disconnected from the connector in the backbone of the frame then threaded through the handlebars to be re assembled in their connector and pluged back into the wiring harness.