Topic: Screwed up my new handlebars

[wvshooter]

Got a set of European style bars from Bike Bandit for my restoration. Nice bars.

So I carefully lay out and drill the right and left positioning holes for the controls. It's about a 1/8 inch hole. Then I lay out the the position of the large holes for the control wires to pass through. Next I drill a 1/8 inch hole as a starter hole for the larger drill bit that's going to make the big hole for the wires to pass through. My brain chooses this moment to go on a break and I proceed to enlarge the positioning hole. Scratch one set of bars.

Aaarrgg!!!

[sandman]

Damn. Can't weld up/fill in the postioning hole enough without discoloring the chrome, or can you? Dial down the mig welder, or tig it, spot in some metal, dremel to correct size. That's what I'd try before buying another set- and it'll be hidden under the switchgear assembly, anyway. You are now presented with another sub-project...let us know if you try jbweld or something!

[wvshooter]

Can't weld up/fill in the postioning hole enough without discoloring the chrome, or can you?

Even if that could be done I'd still know it was under the control and yes I'm anal. I ordered a replacement bar as soon as I buggered the first one. When the bike is done it will be pristine from the tires on up. Thanks for the idea anyway.

[kghost]

Can't weld up/fill in the postioning hole enough without discoloring the chrome, or can you?

Even if that could be done I'd still know it was under the control and yes I'm anal. I ordered a replacement bar as soon as I buggered the first one. When the bike is done it will be pristine from the tires on up. Thanks for the idea anyway.

I know I can't TIG weld it without screwing up the chrome.....

If someone knows how....I'd like to hear it.

Sorry about your bars......maybe hide them in the rafters or something until another project.

[lucky]

Can't weld up/fill in the postioning hole enough without discoloring the chrome, or can you?

Even if that could be done I'd still know it was under the control and yes I'm anal. I ordered a replacement bar as soon as I buggered the first one. When the bike is done it will be pristine from the tires on up. Thanks for the idea anyway.

I know I can't TIG weld it without screwing up the chrome.....

If someone knows how....I'd like to hear it.

Sorry about your bars......maybe hide them in the rafters or something until another project.

Yes there is a way. I have done it.
You TIG weld the hole with stainless then sand it to 500 grit white open face sandpaper. Do not sand the chrome only the stainless. Just the actual diameter of the hole. Then buff.  Most people cannot tell the difference between chrome and stainless. steel polished.

[754]

Weldit then use Blueaway to clean up the chrome.

Myself i would just push a bushing in, if it doesn't block the wires.

If wires are passing by there,make a slip fit bushing with a THIN flange.. Insert from inside,then jam bushing tight with a fod inside the bar, then stake the bushing on the outside with a center punch.