Topic: dammit ive been trying to run my wires through the clubman bar for 4 hours?

[jamesv220820]

anyone got any tricks

[Gordon]

Cut a notch in the switch pods and run the wires outside of the bars.

[jaknight]

Hi James,

I took my 10 wire bundle of wires and wrapped a piece of 20 gauge electrical wire around the bundle just above the electrical connectors.

The piece of 20 gauge was very long.  Then I coated the bundled wires and the piece of 20 gauge with dielectric grease to help them slide through the handlebars.

I pushed the long piece of 20 gauge through the handlebars to the center opening.  Then, I simply pulled on the 20 gauge that was through the opening.......... the rest of the wires follwed through.

Just keep the 20 gauge wrapping as low profiled as you can.  Make the wrap like a spiral, not a large single spot knot.  You know, like a coil spring.........

Did a Heavy Edit...... I first wrote 16 gauge.. it was 20
~ ~ ~ jaknight ~ ~ ~

[coyotecowboy]

.025 MIG wire works great too.  Thats what I used to run the wires in the framerails on my dune buggy

[Burnboy]

heres what I did only took about 20 minutes

Fish some extra wire through. I used abou 2 feet of 18 gauge. Force it in to the elbow and fish it out the other side witha  coat hanger. This will be the hardest part.

Now that you have the guide wire in use some electrical tape on the ends to create and endless loop, like a necklace. You should be able to pull the guide wire and as you pull one end it will feed itself in the other end.

Now get your handlebar switches ready. At first you can tape 2 or 3 wires at a time paralell to the guide wire and as you pull the guide wire it will pull the contrl wires you need through. since it is a loop, once youre wires are through unhook the tape and continue the process. Once you get towards the end youll have to only use one wire at a time because they will bind up on eachother.

Pretty easy, dont use any grease it will only muck things up.

[nippon]

Hi,
an easy way to do this is putting a longer piece of shrink tube over the ends of the cables that they are totally hidden.
Or make a completely new shrink tube from the
begining of the cables to end.
Then, you can put on a piece of welding wire to pull it through.
Or just connect a strong fishing line to the end of the shrink tube. On the other end, connect a small nut.
Just let fall the nut through the handlebar up to the middle hole. Pull the nut out of the hole and pull the cables.

Many ways to do this. But most important is to hide the cables under a tape or tube.
The rubber of the shrink tube will glide easily with some WD-40, too.

If you got the cables on the other side, cut the tube to get free cable plugs again.

nippon

[jamesb]

i took my son outside and showed him what i was doing and bet him 5 dollars there is no way he could those wires through the bars 15 minutes later he comes in and says pay up as we both walked away each of us muttered "sucker".it was definitely worth the 5 bucks. he used soap and wrap the wires with tape in a spiral.i fought with the wires for about 2 1/2 hours myself.

[volkswagendan]

good job!  high five for that one.

[mystic_1]

15 minutes later he comes in and says pay up as we both walked away each of us muttered "sucker"

LOL nice one,  there's using your head.

mystic_1

[jamesv220820]

thanks i will try all those ideas till i get it to work

[jamesv220820]

akright im about to throw this g.d bike away i canceled work and now im approaching 20 hours tryin to do this i dont wanna make it look like crap by running the wires outwside, ive tried fishing line, steel cable, heat shrink ( which was biggest disaster because some came off and is stuck in the handlebar restricting anything now and yes ive done heat shrinking before) umm rope, weights, nuts, hangers, lube, etc.

the most i was ever able to get through was one wire yepdy freakin dah still doesn't help me especially since it was the small group that controls the blinkers and horn , because i have spent 50 dollars alone on random crap that i would think to get the cables through anyone have any other ideas because im gonna go crazy here

thanks

james

[jamesv220820]

wait now 70 dollars people over at ace said a fish tape roll would work they were wrong

[ev0lve]

I couldn't bear the pain of trying to get the wires through the ninety (could barely take running them in a set of Daytona's - which didn't fit upside down - go figure). Other folks on the board have done the drill the end of the inside of the bars trick. Works nicely. Looks good IMO. If I had hair it would have saved me some. 

[ricemoto]

Running wire is always frustrating.  I've wanted to scratch my eyeballs out at times.

Try this one.  Tie a steel washer on the end of a piece of regular string.  Make sure the washer is smaller than the diameter of the inside of the tubing.  Put the washer into the end of the tube and using a fairly strong magnet on the outside of the tubing, drag the magnet along until you get it to the other hole you're trying to reach.  You can now use the string as a pull wire.  Just make sure the string is strong enuf to pull other wires.  I have been installing alarm systems in residences and commercial buildings for a while and have done this inside walls with pretty good success.  The only negative to this is if there is some kind of obstruction but many times you can work around it.  I hope this helps.   

[nippon]

Iggy, are you sure you have mounted each switch on the right side?
It looks upside down to me.

nippon

[papp101]

Nippon,

I have clubmans and his are correct, I know you can mount them both ways though.

[winnipeg550guy]

I couldn't bear the pain of trying to get the wires through the ninety (could barely take running them in a set of Daytona's - which didn't fit upside down - go figure). Other folks on the board have done the drill the end of the inside of the bars trick. Works nicely. Looks good IMO. If I had hair it would have saved me some. 

 This is exactly the way I ran mine as well, easy as pie! with headlight bucket mounted the wires are hardly noticeable, I covered them with this type of expandable sleeving  so it hid the bare wires better.This stuff is great for alot of wiring needs.

[ev0lve]

Iggy, are you sure you have mounted each switch on the right side?
It looks upside down to me.

nippon

Yep, they're on the right sides. Not sure you could get them wrong. I am sure if you could mount them backwards I probably would have.

Another fun tip from the forum is to put some tape on the bars and marker up the posts in the pods then squeeze them on there. It'll make a nice guide for drilling the post and wiring holes.

Best to do an all up fit on the bike as well when figuring out where to drill. I know that seems obvious but it's a mistake I made... obviously