Author Topic: Drilled Clubman Bars (Read 3035 times)

CBNJ74 · « **on:** April 04, 2012, 05:12:44 PM »

Beaten man here. I'm trying to do right by the CB by putting some fresh new repop bars on her. I've got some proper wire coating for the control switches but I can not for the life of me snake the wiring loom through the bars so I've decided to cafe the old girl out.

Does anyone know where I can my hands on some drilled clubmans? or know of someone who drills and sells them? I'd like to use the original controls and not burr them out and run the wires on the outside.

apex_seeking · « **Reply #1 on:** April 04, 2012, 05:40:12 PM »

I've never seen drilled clubmans. Drilling them is pretty easy though. And feeding the loom through can be tricky. But it is possible.

I used the stock bar holes to figure out where I should drill and ran everything inside. I refused to cut on my control cases. Besides, wires outside the bars looks unfinished IMO.

CBNJ74 · « **Reply #2 on:** April 04, 2012, 05:48:40 PM »

Quote from: apex_seeking on April 04, 2012, 05:40:12 PM

I've never seen drilled clubmans. Drilling them is pretty easy though. And feeding the loom through can be tricky. But it is possible.

I used the stock bar holes to figure out where I should drill and ran everything inside. I refused to cut on my control cases. Besides, wires outside the bars looks unfinished IMO.

Where did you drill the exit hole?

gecko672 · « **Reply #3 on:** April 04, 2012, 06:08:40 PM »

I actually just did this, this past weekend. I used the old bars and measured how far in from the ends the holes should go. Cant remember the measurement, but can check.
You have to mount your bars first and rough mount the controls, sit on the bike with hands in position, to work out where your control will be and at what angle. Then you can mark the holes. I put the exit hole in the same position as the originals, on the underside of the bar right in the middle, between the bar clamps.
Pulling the wires was a pain, one side went quick the other side must have had more welding slag inside and took a real lot of pulling and pushing. Lube is the key, plenty of it. If your really giving it some welly while pulling, back off pull the wires back and start again. its easy to catch the plastic wire wrap and rip it all. All and all it was pretty simple. measuring and drilling the holes was the longest part for me.
Good luck

CBNJ74 · « **Reply #4 on:** April 05, 2012, 06:33:12 AM »

Quote from: gecko672 on April 04, 2012, 06:08:40 PM

All and all it was pretty simple. measuring and drilling the holes was the longest part for me.
Good luck

Drilling the holes is where I'm sure I'll have a problem. The bars are only $30. I'd be willing to pay someone that maybe more to do it for me. The repop bars cost me $130!

apex_seeking · « **Reply #5 on:** April 05, 2012, 06:52:22 AM »

I did mine a little different. I ran a single wire through the bars and heat shrinked it into a loop. Then I cut the black sheathing and taped one of the wires to the loop. Pull each wire through individually on the loop. Then rewrap the sheathing on the exposed wires at the exit. Hope that makes sense.

I was nervous about having the wires inside the bar without the sheathing but I haven't had any issues in 3 years and I ran a buddy's bike earlier this year and his has been problem free.

Don't forget to de-burr the holes you drill.

CBNJ74 · « **Reply #6 on:** April 05, 2012, 07:01:01 AM »

Quote from: apex_seeking on April 05, 2012, 06:52:22 AM

I did mine a little different. I ran a single wire through the bars and heat shrinked it into a loop. Then I cut the black sheathing and taped one of the wires to the loop. Pull each wire through individually on the loop. Then rewrap the sheathing on the exposed wires at the exit. Hope that makes sense.

I was nervous about having the wires inside the bar without the sheathing but I haven't had any issues in 3 years and I ran a buddy's bike earlier this year and his has been problem free.

Don't forget to de-burr the holes you drill.

Maybe I'll do that with the repop bars and be done with it. A small piece at the entrance and exit holes. The Thruxton gives me all the cafe I need. I really enjoyed the stock riding position.

apex_seeking · « **Reply #7 on:** April 05, 2012, 07:14:02 AM »

If you're keeping the stockish bars, then I'd give it a go without cutting any sheathing. The 90deg. bend in the clubmans is what gives everybody a headache. I bet you can lube and cram to get the looms through without any cutting.

Elan · « **Reply #8 on:** April 05, 2012, 08:14:16 AM »

yeah I had to also run 2 wired at a time using a "contunuous loop" to pull the wires through.

If your having trouble running the wires through a stock bar, your going to have a lot more trouble trying to run them through a cafe bar. Not to discourage you, but just a heads up.

CBNJ74 · « **Reply #9 on:** April 05, 2012, 08:16:21 AM »

Quote from: Elan on April 05, 2012, 08:14:16 AM

yeah I had to also run 2 wired at a time using a "contunuous loop" to pull the wires through.

If your having trouble running the wires through a stock bar, your going to have a lot more trouble trying to run them through a cafe bar. Not to discourage you, but just a heads up.

I hear ya. I was thinking they would exit straight out at the bend and not running down to the middle like the stock setup.

apex_seeking · « **Reply #10 on:** April 05, 2012, 08:31:09 AM »

Quote from: CBNJ74 on April 05, 2012, 08:16:21 AM

Quote from: Elan on April 05, 2012, 08:14:16 AM
yeah I had to also run 2 wired at a time using a "contunuous loop" to pull the wires through.

If your having trouble running the wires through a stock bar, your going to have a lot more trouble trying to run them through a cafe bar. Not to discourage you, but just a heads up.

I hear ya. I was thinking they would exit straight out at the bend and not running down to the middle like the stock setup.

It's been done that way but it doesn't look very clean.

nomad · « **Reply #11 on:** April 05, 2012, 09:21:14 AM »

Another option for you: D27: 7/8" Cafe Style Bar (Chrome and Knurled with Punched holes for internal Wires) - $110.95

http://www.sideroadcycles.com/ImportedMotorcycles/ImportHandlebars/ImportStreet/78StreetWire.html
(last set of bars on the page)

I went with these. After making the holes a bit larger (elongating them a tad towards the center of the bars using a trusty Dremel), the wires pulled through with no issues at all. I also made the center hole a bit larger. Finally, I cut the bars to narrow them to 29.5" wide instead of the 31.5" they measure from the factory. I have yet to mount them to the bike, but the controls and grips all fit fine.

Elan · « **Reply #12 on:** April 05, 2012, 09:28:05 AM »

you should decide which bars you want without the decision making made by how easy/hard it might be to run the wires. Then you can get the bars that are best for you, and wired up right.

Drilling them is really not that hard. Just a good drill bit(titanium or cobalt), dont drill too fast, use some cutting fluid(keeps the bit cool), and a dremel is also very helpful. The holes you will notice are an oval shape. I made 2 holes for each side of the oval and "connected" the holes using the dremel.

I've done 2 sets of clubmans and both times were a little tedious, but after 45minutes, It was done and I was very happy I did it.

lube those wires! and dont make your holes any smaller (or bigger) than the stock size.

CBNJ74 · « **Reply #13 on:** April 05, 2012, 09:32:24 AM »

Quote from: Elan on April 05, 2012, 09:28:05 AM

you should decide which bars you want without the decision making made by how easy/hard it might be to run the wires. Then you can get the bars that are best for you, and wired up right.

Drilling them is really not that hard. Just a good drill bit(titanium or cobalt), dont drill too fast, use some cutting fluid(keeps the bit cool), and a dremel is also very helpful. The holes you will notice are an oval shape. I made 2 holes for each side of the oval and "connected" the holes using the dremel.

I've done 2 sets of clubmans and both times were a little tedious, but after 45minutes, It was done and I was very happy I did it.

lube those wires! and dont make your holes any smaller (or bigger) than the stock size.

OR you can sell me one of those clubmans

CBNJ74 · « **Reply #14 on:** April 05, 2012, 09:57:32 AM »

Quote from: nomad on April 05, 2012, 09:21:14 AM

Another option for you: D27: 7/8" Cafe Style Bar (Chrome and Knurled with Punched holes for internal Wires) - $110.95

http://www.sideroadcycles.com/ImportedMotorcycles/ImportHandlebars/ImportStreet/78StreetWire.html
(last set of bars on the page)

I went with these. After making the holes a bit larger (elongating them a tad towards the center of the bars using a trusty Dremel), the wires pulled through with no issues at all. I also made the center hole a bit larger. Finally, I cut the bars to narrow them to 29.5" wide instead of the 31.5" they measure from the factory. I have yet to mount them to the bike, but the controls and grips all fit fine.

I do like those black ones. So they're a lower rise than stock?

nomad · « **Reply #15 on:** April 05, 2012, 11:06:08 AM »

Quote from: CBNJ74 on April 05, 2012, 09:57:32 AM

Quote from: nomad on April 05, 2012, 09:21:14 AM
Another option for you: D27: 7/8" Cafe Style Bar (Chrome and Knurled with Punched holes for internal Wires) - $110.95

http://www.sideroadcycles.com/ImportedMotorcycles/ImportHandlebars/ImportStreet/78StreetWire.html
(last set of bars on the page)

I went with these. After making the holes a bit larger (elongating them a tad towards the center of the bars using a trusty Dremel), the wires pulled through with no issues at all. I also made the center hole a bit larger. Finally, I cut the bars to narrow them to 29.5" wide instead of the 31.5" they measure from the factory. I have yet to mount them to the bike, but the controls and grips all fit fine.

I do like those black ones. So they're a lower rise than stock?

These pictures don't show apples to apples since I've already fit everything to the new bar, but it gives you an idea of what my stock bars (I'm guessing they were stock) look like next the the Flander's bars. Yes, they're lower and a bit more forward. I wanted a more agressive position on the bike without going with clubmans. I've read a few comments about how they can kill your back and didn't want to chance them. Also remember that I've cut 2" off of the overall width of the bars... and added bar ends.