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27th May 2008
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Chief Master Mechanic
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Join Date: Nov 2007
Posts: 462 Sportster/Buell Model: XL1200R Sportster/Buell Year: 2004
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Procedure for drilling into bars?
I am going to be receiving some drag pretty soon and I think I am going to attempt to drill and internally wire them. I think that the hole by the controls wont be too hard to do because the bars are dimpled (so the drill bit won't walk). However, the hole in the center of the bars seems like it would be pretty impossible to hold the drill steady on the curved and slippery chrome surface of the bar. What's the proper technique to keep the bit from walking and messing up my new bars?
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27th May 2008
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Biker
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Join Date: Sep 2007
Location: The 6th Canto Of Hell
Posts: 95 Sportster/Buell Model: Nightster Sportster/Buell Year: 2008
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use a drill press and clamp your bars securely when doing so
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27th May 2008
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Bike Builder
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Join Date: Sep 2007
Location: EAST COAST
Posts: 1,830 Sportster/Buell Model: 883r Sportster/Buell Year: 2003 Other Motorcycle Model: cb750 Other Motorcycle Year: 1974
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center punch the spot to be drilled it will help keep from walking and start with a small bit then use a big bit,even with a drill press this will help 
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27th May 2008
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Chief Master Mechanic
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Join Date: Nov 2007
Posts: 462 Sportster/Buell Model: XL1200R Sportster/Buell Year: 2004
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is there an option #2 when you don't have drill press?
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27th May 2008
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Chief Master Mechanic
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Join Date: Nov 2007
Posts: 462 Sportster/Buell Model: XL1200R Sportster/Buell Year: 2004
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Whoops, responded at the same time, Gojira. I think that will be my best bet. Does anybody know the name of the tool I need? The long metal thing that tapers and is used to help hammer in small nails? I think that would be perfect, but I forget what it is called.
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27th May 2008
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Flat Track Racer
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Join Date: Aug 2007
Posts: 243 Sportster/Buell Model: 883 XLH Sportster/Buell Year: 1989
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I used a small bit then worked up. Used a C clamp to hold it in place.
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27th May 2008
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Senior Chief Harley Engineer 2nd Class
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Join Date: Dec 2006
Location: Trinity, NC
Posts: 1,692 Sportster/Buell Model: Black anniversary XL1200 Sportster/Buell Year: 2003
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It's called a center punch or a nail set, and yes that will work fine. One with a slight point will be best but it isn't an absolute must-have.
__________________
Happiness is a motorcycle. Nirvana is a long curvy road.
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29th May 2008
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Senior Master Custom Bike Builder
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Join Date: May 2006
Location: Woodstock, Ga.
Posts: 3,650 Sportster/Buell Model: 1200C Sportster/Buell Year: 2006
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Quote:
Originally Posted by shameless
It's called a center punch or a nail set
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Two different animals, each with their own purposes. While a nail set will work in a pinch (yes, I've used 'em too) if ya gotta go buy one, might as well get the proper one...ask for a center punch.
Could prolly pick one up at Lowes or Home Depot.
__________________
Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well armed lamb contesting the vote!
In a world of deceit, telling the truth becomes an act of revolt.
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29th May 2008
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Biker
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Join Date: Nov 2006
Posts: 82 Sportster/Buell Model: Sportster 883 Sportster/Buell Year: 95
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After you center punch, then start the hole with a "center drill bit". Don't know what that is? Ask the guy at the hardware store. Or, yes you can start with a small drill bit and work up as someone has already said. Center drill bits come in different sizes. I recomend a # 3 for your bar. Without a drill press, and drilling by hand drill, the #3 center drill isn't as likly to break as the smaller sizes. Good luck no matter how you do it.
Ol Rip, retired machinest, tool & die, jig & fixture, mold maker
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