internal bar wiring
Seasoned HDF Member
Joined: Aug 2007
Posts: 8,200
Likes: 3,089
From: NW AR
RE: internal bar wiring
Personally, I would not do it. While it is OK, I guess, for a show bike, I prefer to ride my bike and that means it need to be reliable and not burst into flames or experience a shower of sparks at an inopportune moment. If you really, really want to do that, then double protect the wires with shrink wrap, radius the in/out holes, use gromets, etc. I think I would even consider trying to run something for a conduit like copper tubing or something. Doing it like the TV shows where they fish a wire through then pull the bare wires is just asking for trouble.
Stellar HDF Member
Joined: Nov 2005
Posts: 2,272
Likes: 10
From: Orange VA
RE: internal bar wiring
I have two bikes externally wired and one internally. It cleans up the look but does nothing for functionality. As long as you take the time and effort to do it right you'll be fine. But if you try to low-rent the install you might run into problems down the road such as chafing of the wires, solder breaks, loss of handlebar integrity as a result of drilling them out, etc.
Dr. Hess made some good suggestions for protecting the install. But whatever precautions you take, as long as you use some common sense, you'll be fine.
On my install I used bars specifically made for internal wiring, staggered my solder joints for each wire so I didn't have a huge glob of spliced wires, use shrink tubing to cover the splices, and then used shrink tubing over electrical tape wrap where the wires exit the bottom of the bars. I have no bare wires and no sharp edges that would cause chafing or shorts.
Dr. Hess made some good suggestions for protecting the install. But whatever precautions you take, as long as you use some common sense, you'll be fine.
On my install I used bars specifically made for internal wiring, staggered my solder joints for each wire so I didn't have a huge glob of spliced wires, use shrink tubing to cover the splices, and then used shrink tubing over electrical tape wrap where the wires exit the bottom of the bars. I have no bare wires and no sharp edges that would cause chafing or shorts.
Grand HDF Member
Joined: Sep 2007
Posts: 4,122
Likes: 43
From: Boise Idaho
RE: internal bar wiring
I have internally wired several bikes. It is time consuming and can be a drag to do but it is worth it.
You have to have the proper equipment to do the job right, if you don' t have a drill, die grinder, soldering iron or heat gun.
Don't do it. If you do buy an extra long wire loom and give it a whirl!!
You have to have the proper equipment to do the job right, if you don' t have a drill, die grinder, soldering iron or heat gun.
Don't do it. If you do buy an extra long wire loom and give it a whirl!!
Stellar HDF Member
Joined: Dec 2006
Posts: 2,906
Likes: 11
From: Grottoes Va.
RE: internal bar wiring
It cleans up the bars nicely, but, like stated above, use bars that were ment for internal wireing, drilling out normal bars is risky. Could weaken them.
Just my $.02
Just my $.02
Road Master
Joined: Nov 2005
Posts: 980
Likes: 0
From: Leesburg, Florida
RE: internal bar wiring
I did mine and liked the finished result, but it was a bit of a job. The bars were dimpled for the external wiring. I drilled and elongated the holes to feed the wires into and out of the bars. The hole in the center is between the clamps, and I don't believe the holes in any way weakened the bars.
If you're going to taller or wider bars, by all means buy the wiring extenders. It keeps the installation clean. I extended mine by adding matching wire and soldering them together -- 24 solder joints. Would not do that again; pre-made extenders well worth the price. Of course, if you're going to shorter bars, none of this would be necessary.
If you're going to taller or wider bars, by all means buy the wiring extenders. It keeps the installation clean. I extended mine by adding matching wire and soldering them together -- 24 solder joints. Would not do that again; pre-made extenders well worth the price. Of course, if you're going to shorter bars, none of this would be necessary.
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Road Warrior
Joined: Jul 2006
Posts: 1,351
Likes: 4
From:
RE: internal bar wiring
My bars are internally wired. Did them myself.
Things to prepare for:
Deburr your entrance and exit holes with extreme prejudice. 1 tiny burr can strip a wire and cause a short. Solder all connections, no crimping. Offset your splices and shrink them after soldering. Wrap the entire loom in electrical tape as if you were putting a grip on a baseball bat or wrapping pipes. Slight overlaps as you go.
Take a small nut and put it on the end of some 50lb nylon fishing line and tie the other end wire fishing loom (looks like a small one ended Chinese handcuff and is available at most hardware stores). Put a light coat of dielectric grease on the bundled wires. Drop the nut through the holes and fish it through.. Be patient.
Remember NO BURRS!! Get that yet? Also no burrs inside the bars. This can only be guaranteed by the bar builder or through inspection. Do a dummy run with a piece of lamp cord and inspect the cable for damage after the pull-through.
The guy that built my custom bars told me specifically that he makes sure the internals on his bars are clean, no slag, nosharp edges.
Remember, deburr, solder, shrink, wrap, coat, pull, wipe your pu$$y and get to work!!
If done correctly, there are no worries about shorts, water, etc. Don't believe the hype!
Things to prepare for:
Deburr your entrance and exit holes with extreme prejudice. 1 tiny burr can strip a wire and cause a short. Solder all connections, no crimping. Offset your splices and shrink them after soldering. Wrap the entire loom in electrical tape as if you were putting a grip on a baseball bat or wrapping pipes. Slight overlaps as you go.
Take a small nut and put it on the end of some 50lb nylon fishing line and tie the other end wire fishing loom (looks like a small one ended Chinese handcuff and is available at most hardware stores). Put a light coat of dielectric grease on the bundled wires. Drop the nut through the holes and fish it through.. Be patient.
Remember NO BURRS!! Get that yet? Also no burrs inside the bars. This can only be guaranteed by the bar builder or through inspection. Do a dummy run with a piece of lamp cord and inspect the cable for damage after the pull-through.
The guy that built my custom bars told me specifically that he makes sure the internals on his bars are clean, no slag, nosharp edges.
Remember, deburr, solder, shrink, wrap, coat, pull, wipe your pu$$y and get to work!!
If done correctly, there are no worries about shorts, water, etc. Don't believe the hype!
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Thread Starter
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Tourer
Joined: Apr 2007
Posts: 356
Likes: 0
RE: internal bar wiring
The bars I have do not have holes for the internal wiring, I would have to drill them myself, and I am not sure about that. I will consider it, after I mount the bars up tonight to see if I even like the bars. If I decide to do it, I have to have the bars powdercoated or painted (because they are raw/unfinished right now) so that would take some of the worry away.
Thanks for all the positive feedback
Thanks for all the positive feedback
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