Building Bars???
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6th Gear
Joined: May 2010
Posts: 10
Likes: 0
From: Hilda, Alberta
Building Bars???
So, being a tight penny pincher from the west I don't like spending money. Problem is I just bought a 08 nightster and of course it can always be better, and I wanna make it MINE. I want a set of smaller ape hangers and haven't really seen any that are matching the picture in my head, or the price tag niether. So my thinking is that I am gonna build my own. Wondering if anyone has tried to and if you have any tips. What sort of material should a guy use? Will a mig welder do the trick or should a guy get them tig welded? How hard would it be to drill and dimple them for internal wiring? Any help would be great.
Ultimate HDF Member
Joined: Mar 2008
Posts: 7,604
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From: Landrum, SC , elevation 986'
If its something you want to try doing yourself? Don't, you've already asked the wrong questions.
Find a dam good welding shop and draw them a picture, thats going to be your safest bet.
Oh, yes there are a few guys on here that have made their own bars.
There are also guys on here who have had their bars break and crack. Store bought custom bars and self made ones.
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Find a dam good welding shop and draw them a picture, thats going to be your safest bet.
Oh, yes there are a few guys on here that have made their own bars.
There are also guys on here who have had their bars break and crack. Store bought custom bars and self made ones.
.
Last edited by xFreebirdx; Jun 15, 2010 at 03:50 PM. Reason: Speeling
Thread Starter
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6th Gear
Joined: May 2010
Posts: 10
Likes: 0
From: Hilda, Alberta
And what questions should I be asking? I'm not just some guy doing this out of his basement. I've been welding since I was young young. Living on a farm teaches alot. I have built 4x4 rigs on budget since I was 14, meaning there is alot of fabbing to be done. I also have a friend with a TIG welder, that is alot cheaper than going and paying $60-120/hour shop rate. I have a bender and quite a bit of know how.
Outstanding HDF Member
Joined: May 2008
Posts: 2,230
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From: Mount Holly, NC
get 1inch od tube and get busy. you'll probably have to fab a dimpler. maybe use a piece of 1/4 inch solid stock and a press? theres a knurling tool floating around the internets. or you can use a punch... the knurling tool aint cheap.
tractor supply carries 1" od tube pretty cheap. a lot cheaper than mcmaster carr.
tractor supply carries 1" od tube pretty cheap. a lot cheaper than mcmaster carr.
Outstanding HDF Member
Joined: Feb 2009
Posts: 2,228
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From: New Port Richey FL
you need DOM tubing, not just some random pipe; that will work the best. Also you can absolutly weld them up with a MIG, thats how i made mine. I didn't dimple or drill my bars for wires so I can't help there but I hope some of that info helps. I can't remember the exact thickness of the DOM tubing...I tried to find it but i don't have it....I think i used some pritty thick stuff just to be safe...something like 1/8"...but with DOM its always in decimals.
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1/8" is 0.125. You definitely want to use tube instead of pipe. Tube is structural material and is measured by the outside diameter. Pipe is a transporting vessel and is measured by the inside diameter.
If you don't have a local supplier you can order what you need from www.onlinemetalstore.com
You can also use aluminum tube but you'll want a larger wall thickness than 0.125.
MIG welding the bars will be plenty but TIG usually looks alot better.
And if you are planning on internal wiring you won't need to dimple the bars.
If you don't have a local supplier you can order what you need from www.onlinemetalstore.com
You can also use aluminum tube but you'll want a larger wall thickness than 0.125.
MIG welding the bars will be plenty but TIG usually looks alot better.
And if you are planning on internal wiring you won't need to dimple the bars.
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Thread Starter
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6th Gear
Joined: May 2010
Posts: 10
Likes: 0
From: Hilda, Alberta
1/8" is 0.125. You definitely want to use tube instead of pipe. Tube is structural material and is measured by the outside diameter. Pipe is a transporting vessel and is measured by the inside diameter.
If you don't have a local supplier you can order what you need from www.onlinemetalstore.com
You can also use aluminum tube but you'll want a larger wall thickness than 0.125.
MIG welding the bars will be plenty but TIG usually looks alot better.
And if you are planning on internal wiring you won't need to dimple the bars.
If you don't have a local supplier you can order what you need from www.onlinemetalstore.com
You can also use aluminum tube but you'll want a larger wall thickness than 0.125.
MIG welding the bars will be plenty but TIG usually looks alot better.
And if you are planning on internal wiring you won't need to dimple the bars.
What would the advantage of using aluminun? I want black bars so there is no advantage there. Sure they will be lighter, but it is a harley, so i dunno if that is a real issue. Also you say I won't need to dimple them for internal wiring? How do you internal wire them then, or is there enough room for wires in the controls?