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Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders Discuss Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders problems, advice, and/or how tos.

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  #1  
Old 23rd February 2012
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Default bar drilling

hey folks. all my stuff finally arrived for my bar change out.

got some sweet 12" apes from biltwell however they are dimpled.

going to need to drill them to wire internally, but heres where i need the help - where in the dimple do i drill the hole for the wire to enter the bars?

ive taken a pic and color marked some positions where i think i should drill. please have a look and let me know which color is the right area! this is the left hand clutch side:




thanks for all the help guys it is much appreciated
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Old 23rd February 2012
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Put your hand controls on it and look it will be staring at you. I always drill in the middle, your red dot. Then i get a die grinder out and widen and smooth towards the blue and yellow dot. The more oblong you make it, the easier it will be. make sure you run the die grinder in the bar to get rid of any burs, or a hand file. spray some juice on your wires and they will slide in nice
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Old 23rd February 2012
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thanks madnss, will give it a go!
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Old 24th February 2012
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I like to drill mine where the yellow circle is. I use three different size bits for the control holes. I start with 1/8", then 3/8" and finish with 1/2". I start the 1/8" straight, but by the time I get to the 1/2" I've angled the drill bit so the wires will have more of a straight shot into the bars. For the wiring exit slot I drill three 1/8" holes first and then follow that with the 3/8" bit so the holes just touch. You can wiggle the bit to connect the holes. Sometimes I just get a small cut off wheel on my dremel to finish the slot since I'm going to use the dremel next anyway. After holes are drilled and exit hole is slotted I put a small fine sanding drum (1/4" x 1/2") on the dremel and carefully clean up the sharp edges.

Also, make sure to protect the rest of the bar. I use a couple layers of blue tape around the hole area I don't want accidentally damaged. I cover the rest of the bar with some shop rags held on by blue tape. This is especially helpful with black bars. They scratch very easily and the drill bit or dremel can sometimes get away. Accidents happen. For the black bars I finish the bare areas with touch up paint. For chrome I'll use some clear nail polish to seal it and prevent any rust.
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Old 24th February 2012
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where you have the yellow circle ,is where I drilled mine(1/2")
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Old 24th February 2012
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Quote:
Originally Posted by roadtrip View Post
where you have the yellow circle ,is where I drilled mine(1/2")
exactly what i did on my friscos
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