Topic: Drilling handlebars = suicide?

[Tim.]

So, I'm replacing my stock bars with drag bars, that have some pull-back.  My transitory step towards clubmans or clipons.

Anyhow, I have brand-new controls that cost a small fortune on my bike, and while the starter/kill (right) controls have a cast-in notch to allow exterior wiring, the left controls do not.

I really don't want to take the dremel to my controls to allow for exterior wiring, and prefer the neat and tidy look anyhow.  So, I'm planning on drilling/grinding out the appropriate holes in my new bars to accomodate the wiring.

I can't see why this would be an issue, assuming of course I keep the holes to a minimum size, the same as designed by all those smart Japansese engineers back in the 70's for my OEM bars.

Thoughts?  I'd hate to have my bars turn into origami while whipping around an on-ramp on the 401 up here.

[Daves_76_SS]

I put the same type of bars on my bike.  When I started dremling the holes for the wires the chrome started to chip and peel off.  So be very careful of that.  I ended up running the wires very neatly on the outside of the bars.

[Jonesy]

You might want to use an end mill to cut the holes. The holes will be neater (you can make the nice slotted hole at the steering neck where the wires come out) and you won't have the drill get ripped out of your hand when the bit goes halfway through and catches on the other side.... (Don't ask me how I know this..

[scout18]

If you score the shape that you are going to cut in the bar first it should not chip out the chromeas long as you stay inside the score line. Idid this on my 350 butused balck painted bars

[crazypj]

The only thing you have to be careful of is to make sure you deburr the holes so you dont get stress cracks (drill, file and polish with a dremel) Aftermarket bars are frequently thicker material than the stock ones)
PJ

[Tim.]

Glad to hear others have done it and lived to tell the tales.  I may simply mark the areas and have my local machine shop do the dirty work.  I don't have a drill press, or even a solid vice to hold the bars while working, so we'll see what I end up doing.

Thanks for the input!  Will post pics when I get the bars mounted.

[hopterfixer]

I drilled mine mounted on the bike.  I stepped up drill bits from a #40 pilot hole, then used a rotary carbide cutter to further widen the hole.  I finished the holes by filing them very smooth.  When I installed the wiring I wrapped the harness very tightly with electrical tape and lubricated it very generously.  Good Luck!

[ProTeal55]

When I started dremling the holes for the wires the chrome started to chip and peel off. So be very careful of that.

Go to your local automotive paint supply house and get some green 3M bodyshop tape. Wrap the bars in a layer or two before you notch / drill whatever holes you need. The tape will keep the finish (chrome) from being damaged during the drilling process...

[Chris Liston]

Proteal,

kick but avatar.  Sorry to jack the thread.  Do you have those things on random?

[ProTeal55]

Proteal,kick but avatar. Do you have those things on random?

Naw , just bored at work with allot of pics I wanna use.
If someone knows of some sorta slideshow avitar program please let me know...

Back to the topic....

[mgilvary]

I drilled a set of drag bars last year, and just drilled a set of clubmans a few weeks ago. I don't think there's any problem with it. The handlebars are quite strong, and, if you think about it, they really aren't taking a lot of weight anyway.

As I think I mentioned in another thread a while back, I dropped my bike on my drilled drag bars with enough force to mangle my barend mirror. The handlebar didn't suffer one bit, and it was supporting much of the bike's weight.

[Tim.]

I drilled a set of drag bars last year, and just drilled a set of clubmans a few weeks ago. I don't think there's any problem with it. The handlebars are quite strong, and, if you think about it, they really aren't taking a lot of weight anyway.

As I think I mentioned in another thread a while back, I dropped my bike on my drilled drag bars with enough force to mangle my barend mirror. The handlebar didn't suffer one bit, and it was supporting much of the bike's weight.

They don't support much weight under normal circumstances to be sure, but it's in an emergency that you don't want the bars bending and snapping, and of course this is when the bars are under the most stress.  I'm comfortable now that this is all good - just wanted some real life experience input before I break out the drill.