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Drilling new bars

Discussion in 'Motorcycle Tech Talk' started by lowrider92, Jan 26, 2008.

  1. lowrider92

    lowrider92 New Member

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    I just bought new mini ape handlebars and want to run the wires through them. They have a hole in the bottom at the cross bar between the risers for the wires to exit, but they are not drilled at the switch housings. My question is, do I drill the holes on the bottom side of the bars or does it matter where I drill them. Where is the best place? I have new harness that are 48" long with new switches but I need a little help on the location of the holes. I don't want to screw-up a set of 300.00 custom bars.
    lowrider92, Jan 26, 2008
    #1
  3. chucktx

    chucktx Moderator Staff Member

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    figure out where the grips are gonna sit. mark it. use tape to hold your switches, if they are seperate from the grips. mark the holes and drill, making sure you debur the holes.....sit on the bike and make sure all is comfy before drilling.....and remember...............measure twice, drill once!!!!:D
    chucktx, Jan 26, 2008
    #2
  4. maxpower_hd

    maxpower_hd Active Member

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    I used a trick I found on here somewhere to get the wires through the bars. I used orange nylon masonry string.

    1) I tied a knot in the end of the string and put it into the hole where I wanted the wires to come out.

    2) I taped up all the other holes with painters tape except the one that the wires were going to feed into.

    3) I blew compressed air into the hole I placed the string in and POOF! Like magic it came out the other end.

    4) Then I pulled the wires through the bars with the string.

    It worked great. Good luck.
    maxpower_hd, Jan 30, 2008
    #3
  5. wvak47

    wvak47 Active Member

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    Weedeater string works well too if you don't have air. Works more like fishtape.
    wvak47, Jan 30, 2008
    #4
  6. lowrider92

    lowrider92 New Member

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    Thanks for the help you guys, I new I could get some answers.:)
    lowrider92, Jan 30, 2008
    #5
  7. hotroadking

    hotroadking Super Moderator Staff Member

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    Be carefull drilling and be sure you clean up the cut ends with a dremel and or file, nothing like sharp edges to chafe then cut and ground out a wire,

    I drilled mine out in the depression area under the controls, did an elongated hole vs. a straight in hole, that way the wires naturally would go into the hole.

    Also, I pulled off the protective black cover on most of the wire bundle but left enough on so when I pulled the wires through the black plastic cover went into the hole to protect the wires.

    I put more of the black plastice cover on the other end where they exited the bars for looks and protection.

    The string works, or weed eater line, or old used guitar strings.

    I put a small washer on the end of the string and just let it fall and gravity did the work.
    hotroadking, Jan 31, 2008
    #6

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