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Drilling Handlebars?

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Old Jan 16, 2021 | 06:39 AM
  #11  
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Originally Posted by curt5911
Would drilling 1/2 holes in the bottom of the elbows impact the structural integrity of the bars?
It would turn the handlebars into scrap.

Originally Posted by curt5911
I used a string tied to a nut and tilted the bar until that fell through
Here is how we get a pull string through a long tube in the experimental jet engine world:

A length of string, maybe a small knot at the starting end, put it into the tube, then stick an air nozzle into the tube and give it a shot of air. Hang on to the other end or the whole string will pass through...
 

Last edited by Dan89FLSTC; Jan 16, 2021 at 06:45 AM.
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Old Jan 16, 2021 | 06:46 AM
  #12  
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super duper +1 mr. dan
hadn't heard that old trick in a long time. we used to shoot ping pong ball down long conduit runs.
 
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Old Jan 16, 2021 | 08:22 AM
  #13  
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Originally Posted by curt5911
Yes I was. Every time I saw the expandable nylon cable sleeving mentioned I thought people were just using it to pull the wires through. KST includes a piece to do that with their kits. I did end up slicing the TBW on my road glide bars and taped it the entire length which made it pretty non flexible. I can’t find any locally. Would heat shrink tubing work just as well? That’s available locally. And thanks.
A YouTuber named skydude426 has a 6 volume series demonstrating internal wiring. In vol 3 he shows the wiring with the oem nylon sheathing removed and applies the nylon sleeving. Doing this makes life so much easier and makes for a clean looking finished job. Some installers will leave the wires bare and pull them thru. This works well too, I just wasn’t comfortable dragging bare wires around bar corners. Not sure where you are but shouldn’t be hard to find nylon cable sleeve. Can also be found online I’m sure. I don’t believe shrink wrap would be very flexible. I’d go sleeving, electrical taping or bare wires in that order. Regardless get rid of the oem sheathing. Just leave enough at the housing to tuck in the open hole at the bar end.
 
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Old Jan 28, 2021 | 04:30 PM
  #14  
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I always remove stock sheathing and replace with shrink tubing. Bundle the wires as round in shape as you can and heat. I use guitar strings to pull the wire as you can get a good 180* bend and cover end with shrink tubing. I’ve never failed to get wires thru bars using this method. When you get a tougher pull a shot of non chlorinated brake cleaner freezes the wire long enough to pull your wire easily. If you have pc’ed bars be careful not to get the brake cleaner on the coating,it will be toast. G.
 
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Old Jan 28, 2021 | 05:03 PM
  #15  
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[QUOTE=. (When you get a tougher pull a shot of non chlorinated brake cleaner freezes the wire long enough to pull your wire easily.)[/QUOTE]

lol I see what you did there....never had that problem!
 
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Old Jan 28, 2021 | 09:43 PM
  #16  
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Neither did I till I tried to get 8 wires thru a set of 6” high Z bars. Apes and Beach bars are a breeze.
 
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Old Jan 28, 2021 | 11:07 PM
  #17  
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Never mind....
 
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