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?

 

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

 

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.

 

I would just use a drill bit and enlarge the hole already there.

 

Die grinder, can't believe I didn't even think of that. Thanks man.

 

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

 

A die grinder with a burr bit or a dremel with a grinding bit.

 

x2 on die grinder

 

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.