What size hole for wires?
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Joined: Dec 2005
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What size hole for wires?
Getting ready to install some new (1")handlebars ,2000 Standard, factory controls, Iwant to run the wires in the bars. What size hole do I need to drill? 7/16th looks about right . I'm going to elongate the center holes & deburr everything.
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Joined: May 2006
Posts: 31
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From: Sedan, South Australia
RE: What size hole for wires?
Hi there,
Well, just went out to the garage and measured the holes I drilled in previous stock HD bars to pass stock wiring harnessess (FXD, FLHRCI, FLSTC) and an 8 mm drill bit is what you need (after passing a small diam pilot hole of course) - as you say, oval the hole out to 10mm and deburr the whole lot. The middle hole at mid risers should be well ovalled to pass both harnesses L & R. As you know, soap up the harness after passing a leader wire through the bars, and pull the harness through.
With the dimpled HD stock bars its nice and easy to do this job - site your entry hole at the very end of the dimple - this gives you an easy entrance for your wiring harness as it dives into the bar and not too sharp an angle which can lead to chaffing of the harness sheath and worse. (By my calcs a 7/16th drill bit would be an overkill to start with).
John
Well, just went out to the garage and measured the holes I drilled in previous stock HD bars to pass stock wiring harnessess (FXD, FLHRCI, FLSTC) and an 8 mm drill bit is what you need (after passing a small diam pilot hole of course) - as you say, oval the hole out to 10mm and deburr the whole lot. The middle hole at mid risers should be well ovalled to pass both harnesses L & R. As you know, soap up the harness after passing a leader wire through the bars, and pull the harness through.
With the dimpled HD stock bars its nice and easy to do this job - site your entry hole at the very end of the dimple - this gives you an easy entrance for your wiring harness as it dives into the bar and not too sharp an angle which can lead to chaffing of the harness sheath and worse. (By my calcs a 7/16th drill bit would be an overkill to start with).
John
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