Drilling Bars....
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Cruiser
Joined: Feb 2008
Posts: 143
Likes: 0
From: Clarksville, IA
Drilling Bars....
Anyone ever drill your own bars for internal wiring? Was it worth it or was it a pain in the a$$? What diameter holes are required?
I'm doing a conversion to a Sporty Custom riser/drag bars and I am limited to 1" bars. The only 1" drag bars I can find that are drilled are over $100. I'm thinking about buying a set of cheapies just to try it.... can't hurt right?
I'm doing a conversion to a Sporty Custom riser/drag bars and I am limited to 1" bars. The only 1" drag bars I can find that are drilled are over $100. I'm thinking about buying a set of cheapies just to try it.... can't hurt right?
Elite HDF Member
Joined: Sep 2008
Posts: 4,440
Likes: 148
From: Northwest
Anyone ever drill your own bars for internal wiring? Was it worth it or was it a pain in the a$$? What diameter holes are required?
I'm doing a conversion to a Sporty Custom riser/drag bars and I am limited to 1" bars. The only 1" drag bars I can find that are drilled are over $100. I'm thinking about buying a set of cheapies just to try it.... can't hurt right?
I'm doing a conversion to a Sporty Custom riser/drag bars and I am limited to 1" bars. The only 1" drag bars I can find that are drilled are over $100. I'm thinking about buying a set of cheapies just to try it.... can't hurt right?
So I would say, install the new bars first and make all the other necessary adjustments. If you like them enough to stay, then do the internals.
Advanced
Joined: Dec 2008
Posts: 87
Likes: 0
From: Brewster NY
SUPER EASY!!! set the controls on the bars and mock up how you want them to sit. mark the hole and as far as the size of the hole is concerned it depends on the set up you have, but use a very small bit to start a pilot. once it's drilled ream the hole and fish safety wire through, tape to the wires and pull it through. drilling your holes is nice cause if you want the bars set up on a slant or a little awkward they look really clean.
Road Warrior
Joined: Apr 2008
Posts: 1,393
Likes: 8
From: Ohio
I dimpled mine with a sharp nail so the drill bit wouldn't dance around. And I started small and worked my way up to a larger bit. It's critical that the sides of the hole are smooth so they do not cut into the insulation when you drag the wiring through, or worse, vibrate through when you are doing 75 on the highway at night coming around a curve with a semi behind you and a backhoe in the oncoming lane with a light glaze of dew on the road, no shoulder, and a couple of beers in you. But sometimes I worry too much........
Elite HDF Member
Joined: Apr 2007
Posts: 4,919
Likes: 23
From: Seattle, WA
Anyone ever drill your own bars for internal wiring? Was it worth it or was it a pain in the a$$? What diameter holes are required?
I'm doing a conversion to a Sporty Custom riser/drag bars and I am limited to 1" bars. The only 1" drag bars I can find that are drilled are over $100. I'm thinking about buying a set of cheapies just to try it.... can't hurt right?
I'm doing a conversion to a Sporty Custom riser/drag bars and I am limited to 1" bars. The only 1" drag bars I can find that are drilled are over $100. I'm thinking about buying a set of cheapies just to try it.... can't hurt right?
I dimpled mine with a sharp nail so the drill bit wouldn't dance around. And I started small and worked my way up to a larger bit. It's critical that the sides of the hole are smooth so they do not cut into the insulation when you drag the wiring through, or worse, vibrate through when you are doing 75 on the highway at night coming around a curve with a semi behind you and a backhoe in the oncoming lane with a light glaze of dew on the road, no shoulder, and a couple of beers in you. But sometimes I worry too much........
R/
Priest
Road Warrior
Joined: Apr 2008
Posts: 1,393
Likes: 8
From: Ohio
Purely. I don't trust myself to drive a lawnmower after drinking, so I probably would be roadkill on a bike.
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Road Master
Joined: Sep 2008
Posts: 1,240
Likes: 0
From: Milwaukee area
I just drilled my stock bars this past weekend. I went to 15/16" for the holes. I drilled into the corners of the dimples at the control end and slotted the bottom. Internal wiring really makes a difference on a pretty much stock bike.
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Cruiser
Joined: Dec 2008
Posts: 133
Likes: 0
From: central ill
ummm
after drilling your holes.tape up both sides of bars(where your grips are)hand feed some yard in one hole and blow it through with compressed air it will shoot out the other hole.then tape our wires and pull them through