handle bars

[Nightengale]

i am going to try and make some new handle bars for my bike, since mine were damaged in a recent accident that i was in. I had a guy pull out in front of me and then slam on brakes, so i had to lock up the brakes and ended up laying the bike down so as not to slam into the back of the truck. the only thing that was damaged was my handle bars got bent on the left hand side, and i didnt even get a scratch. but any way i was thinking of making a new set of bars, but i want 1" instead of 7/8", and dont want to have to change out the handle bar clamps. so what i am going to do is use 7/8" where the clamps are and 1" every where else. so that i have more of a selection when i comes to hand controls and grips. I will take some pics as soon as i get started.

this is my idea so far.

[DGXSER]

First, glad your all right and this is the worst of your damage!

The only thing I am thinking is that you want to make sure you have room for all the controls after your reinforcing brackets. Also keep in mind that any sharp angles or points on the bars could end up in your head the next time someone pulls that stunt on you. (Yes, there will be a next time.)

Of course the 1" controls will not be stock XS11, and require wiring modifications, but I seem to recall you have been pretty far down that path to begin with.

[GLoweVA]

Sorry about your little mishap. These drivers around here SUCK!
With that apprenticeship, you'll have all kinds of stuff to work with about making you new bars. I can't wait to see pics!

[fredintoon]

Negatory ugly gussets

Hi John,
gussets are for those as can't weld.
And they look ugly.
And they'll get in the way.
And if they are put anywhere they should be at the 7/8" to 1" junctions where the most stress is.
Pay the money and get the bars professionally TIG welded.

[jwhughes3]

Use risers to convert 7/8" clamps to bigger bars. Then just choose the 1" bars you like.

http://m.motorcycle-superstore.com/I...mStyleId=47915

John

[Nightengale]

welding

Hi John,
gussets are for those as can't weld.
And they look ugly.
And they'll get in the way.
And if they are put anywhere they should be at the 7/8" to 1" junctions where the most stress is.
Pay the money and get the bars professionally TIG welded.

i have access to a profesional machine shop/ motorcycle shop with all the proper tools to do these right. the gussets were just for decoration. i made the bars that are currently on my bike.



when i layed the bike down it hit on the left hand grip and only bent the bars and none of my welds broke

[Yard Dogg]

I like the design. Details make the bike. I agree with finding 1 inch risers. Also, you would loose some strength and have an ugly weld where the 7/8 transitions to the 1". You could put spacers in between your clamp halves, then bore them out to 1". Use the spacers to make sure they will clamp down with bite after being bored.