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Question about changing handlebars

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Old Nov 14, 2022 | 05:24 PM
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Default Question about changing handlebars
I’m changing out my stock road king special bars for some carlini evil apes, I notice that the hole for the wires to exit the bar at risers is quite a bit smaller than the stock bars opening, also it faces down whereas the stock one faces forward. I don’t MIND de-pinning all the connectors but it seems like a huge pain in the *** and I was wondering if anyone’s ever milled the hole out to make it larger, if so what’d you use.. router?

 
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Old Nov 14, 2022 | 05:28 PM
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I have opened the whole on many bars with no issues, just dont go too big and no sharp corners, keep it round if possible. There is magic in pie.
 
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Old Nov 14, 2022 | 06:09 PM
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Originally Posted by Taxgod4u
I have opened the whole on many bars with no issues, just dont go too big and no sharp corners, keep it round if possible. There is magic in pie.
I was hoping to be able to file it down so the edges are smooth, I just need to find the right tool for the job. Fortunately everything is covered up so it doesn’t matter if I ding up the powder coating
 
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Old Nov 14, 2022 | 07:31 PM
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A drill press, a tungsten die grinder, a drill if you use a punch first. I would not use a router. Keep it as small as possible, and use the file you have to round the sharp corners.
 
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Old Nov 14, 2022 | 07:58 PM
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I would just use a drill bit and enlarge the hole already there.
 
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Old Nov 14, 2022 | 08:25 PM
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Originally Posted by NoRegerts
A drill press, a tungsten die grinder, a drill if you use a punch first. I would not use a router. Keep it as small as possible, and use the file you have to round the sharp corners.
Die grinder, can't believe I didn't even think of that. Thanks man.
 
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Old Nov 14, 2022 | 08:27 PM
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Originally Posted by Hawg Runner
I would just use a drill bit and enlarge the hole already there.
If it was just a circle I would use my step bits. It's an oval tho, I don't know if I could get it good enough with a regular drill. Id love to own a drill press
 
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Old Nov 14, 2022 | 09:58 PM
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A die grinder with a burr bit or a dremel with a grinding bit.
 
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Old Nov 14, 2022 | 10:23 PM
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x2 on die grinder
 
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Old Nov 15, 2022 | 07:56 AM
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Originally Posted by stanley88
Die grinder, can't believe I didn't even think of that. Thanks man.
I'm always doing something and you'd be amazed at the simple thing I sometimes forget. No worries and I hope it works out well for you.
 
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