Topic: Best way to drill holes in handlebars

[jonathantaylor86]

I have a 72' Cb500 that i am switch over to drag bars.  I would like to know the best way to drill the holes for the switches?

[westondc]

i'm wondering the same thing for the same year and bike, weird... i was told over the weekend that a dremel works pretty well. most of the guys at the bike show said they didn't bother running the wires through the handle bars but I think i will when i replace the bars with euros this weekend.

[jonathantaylor86]

I was thinking of using the dremel, but I haven't any bits at the moment. Anyone know what kind of bit would work best?

[City Boy]

Hi gang.I installed flat bars on my K0 as soon as I had it uncrated.The hole for the locating pins is the most critical.Measure twice,drill once.The opening for the wires is not so critical and the dremel bits will be much faster than the hand filing method which I employed.The holes in your existing bars will help in your measuring.Good luck and Rock On

[vames]

I agree that the locating pin is the most crucial -- make sure you get the levers exactly where you want them to be.

For the wire holes, I used a dremel with a little metal cutting wheel and carefully sliced out the hole. used a file to debur before sending the wires through with a lot of wd40.

[754]

Vertical Milling machine...

 If you dont have that, centrepunch carefully, then drill.

[MCRider]

Vertical Milling machine...

 If you dont have that, centrepunch carefully, then drill.

Yeah. I chucked mine in the "pipe" jaw of the vice. Centerpunch for the ends of the oval shaped hole where the wires go. Use a real sharp (new) drill bit (s). Maybe stage it up, don't drill it all at once. Then use the dremel to connect the holes.

[fletcha221]

Drill press! Start with a very small bit. FILE EDGES WHEN YOU ARE DONE, or your handlebars will eat wires:)

[Steve F]

If you're concerned about the placement of the locating holes, try inking up the area on the bars with a black Sharpie pen, mount the control loosely where you want it, and gently and with small movements, rock the control back-and-forth on the bar to remove the ink where the pin sticks out.  That's where you drill the hole.  Since chrome is really hard to drill through, I would recomment that you centerpunch the mark, and using a grinding tip in the Dremel, remove the chrome from around the centerpunch mark before drilling.  Where the wires exit the bars, you need an elongated hole or slot to get the wires through, and this is where a carbide burr bit in the Dremel comes in handy.  The slot I made was around 1/4" w x 7/8" long.  JUST BE REALLY CAREFUL THAT YOU ROUND THE EDGES INSIDE THE BARS WHERE THE WIRES ENTER AND EXIT.
Steve F

[SKTP]

I have done 2 sets of bars, both with a dremel...I made a paper template from the old bars to get the holes in the right locations...taped the templates to the new bars and used those as a guide...cutting the big egg/oval part takes the most time with the cutting bit...but its not very difficult...keep checking to see if the wires will fit and cut as little as possible so the control housing covers your holes...

[MJL]

Vertical Milling machine...

 If you dont have that, centrepunch carefully, then drill.

Plasma torch...

[Noel]

I use a jig like this one: http://www.vansantent.com/Punch_Drilling/drill_rite_drill_guide.html

[hs2k007]

for the dremel, a carbide cutting tip will be the best.  It will cut hardend steel, so it will cut the chrome.  you can get them at a hardware store or walmart

[nancy]

I just did a new set of bars for my cb750 and drilled the wiring holes with a standard drill bit, with the drill mounted on a bench drill-press. Used some gaffa tape and wrapped the area Ize drilling, to prevent the bit slipping. Finished the holes with a small file. The metal is soft and easy to work. Start with a small hole and make it bigger.