Topic: Tommaselli clip-ons and internal wiring

[tacc13]

Wondering if anyone has had any luck running wires internally in these clip-ons? I have motogadget switches and while the hole for the entry point is easy enough to drill, I'm not sure about where to put the other hole to get the wires out. I'm not wedded to internal wiring, but it would look neater if possible.

Thanks

[calj737]

This approach works very well for me. I drill a hole on the plastic end cap (tank side) then sheath the wiring and secure internally with some heat shrink. Pass this thru a rubber grommet installed in the end cap and terminate the wiring down the backbone.

[DaveBarbier]

Tommaselli's have those elbows that connect the bars to the clamp, right?



Might be a little ugly if the wires exited the elbow. Maybe you could route them down through the elbows?

[Rookster]

Just my opinion, but don't drill the bars.  You will be supporting alot of your weight with your hands/wrists and this puts pressure on the bars.  Drilling a hole in the bars reduces their strength.  Make a nice half circle cut out in the switch case with a dremel and run the wires on the outside.

Scott

[tacc13]

Thanks for the replies. I've decided to go external with the wires. The elbows have bolts through them and I can't see any way of going internally without either destroying the bars or having a result that looks plain ugly.


For calj737 - the wiring looks great. Where did you get the braided housing and the clips on the frame backbone?

[calj737]

McMaster Carr. Order the non-fray type of polyester.

[Schalk]

I have the same clip-ons from Tomaselli and the same issue with how to route the wiring. Can anyone please share some photos of how you eventually solved the wire routing problem? I intend to use switches and bar-end turn signals from Motogadget and would prefer not to cut the nice switches... Also, I cannot see how to use the bar-end indicators without drilling an exit hole near the triple clamp?

[PeWe]

A std bar with holes for wiring?  My K2 project will get this for a clean OEM look.
https://www.davidsilverspares.co.uk/CB750K2-FOUR-1972/part_188998/

[calj737]

I have the same clip-ons from Tomaselli and the same issue with how to route the wiring. Can anyone please share some photos of how you eventually solved the wire routing problem? I intend to use switches and bar-end turn signals from Motogadget and would prefer not to cut the nice switches... Also, I cannot see how to use the bar-end indicators without drilling an exit hole near the triple clamp?

There is no way to route the wires internally from the switches to the m-unit without drilling an exit hole. “What goes in, must come out...somewhere”

[BomberMann650]

Cal can wire my bikes any time!  👌🏻👍🏻

[Schalk]

Hi tacc13, can you please share a few photos of how you went externally with the m-switches and tomaselli clip-ons?

[tacc13]

Sorry for not getting back, my build is progressing a lot slower these days and I unfortunately don't drop by these boards as much as I should. As luck would have it I am building the wiring harness and revisited this post. I wasn't going to drill the bars but was on the Revival Cycles site and they sell Tommaselli bars and offer a service prepping them for internal wiring. I emailed them and Stefan replied that they can be drilled on the cast elbow in line with the centre of the bar, for the exit hole. He also said the bars themselves are thick so are safe to drill, but keep the hole below 3/8". One possible issue is that they need to be internally machined to take the Motogadget blinkers. Revival offer that service. Hope that helps. If I can get my harness sorted in the next few weeks I will tackle the bars and post a photo.

[tacc13]

Posted some photos in the project board of one of the bars drilled for internal wiring.