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Mill to 1" bars

  • Thread starter Thread starter jmlcolorado
  • Start date Start date
J

jmlcolorado

Guest
Hey guys.

Whats the best way to mill out the stock tree to accept 1 inch bars rather then 7/8" ?

I want to be failry precise but can only do so much in the garage and would rather do it in the garage rather then take em to a shop abd let someone else do it.

Thanks
 
jmlcolorado said:
Hey guys.

Whats the best way to mill out the stock tree to accept 1 inch bars rather then 7/8" ?

I want to be failry precise but can only do so much in the garage and would rather do it in the garage rather then take em to a shop abd let someone else do it.

Thanks
Click to expand...

Bring a one inch bit, you can use my drill press.
Why would you want fatter bars?
 
I'm not saying it can't be done, but it's risky trying to open up a hole this size in aluminum without a fairly rigid setup. A reamer may work better than a drill. Having to find a replacement top clamp and/or a visit to the ER will likely cost more than a trip to the machine shop.
 
gearman said:
I'm not saying it can't be done, but it's risky trying to open up a hole this size in aluminum without a fairly rigid setup. A reamer may work better than a drill. Having to find a replacement top clamp and/or a visit to the ER will likely cost more than a trip to the machine shop.
Click to expand...

im with this guy ^^^^^^^ +1

Jake
 
I want larger bars mainly because i am going to a twist style clutch setup. Cleaner look in the front with hidden cables for throttle and clutch.
 
1" ball end mill.

that will be real cool way to waste money and time.
I think you would have a better time with forward controls and a foot clutch, linked brakes and a dry sump oil system. webber grill on the tail.
and a DVD player on the triple trees.
 
I'm pretty sure if trying to go from 7/8 to 1" on the stock clamps you will be very close to if not into the mounting bolts :-k

check it out before you start mate :)
 
trippivot said:
1" ball end mill.

that will be real cool way to waste money and time.
I think you would have a better time with forward controls and a foot clutch, linked brakes and a dry sump oil system. webber grill on the tail.
and a DVD player on the triple trees.
Click to expand...
bit unfair mate, if thats what the guy wants then let him do it, we may learn by our mistakes but then we all like to personalise our bikes in our own way, some things work, some dont, but if you come up with an idea and it works then its a good feeling
 
trippivot said:
that will be real cool way to waste money and time.
I think you would have a better time with forward controls and a foot clutch, linked brakes and a dry sump oil system. webber grill on the tail.
and a DVD player on the triple trees.
Click to expand...


Ya see thats why i love this beautiful contry i live in. Im free to have my own taste. If you were to prefer a hot pink bike with shoestrings for your handlebars and a Cordless drill as a motor, that would be fine. Just not my taste.

I would like to have a twist style clutch on MY bike, hence why im building MY bike and not yours.

Im always open to constructive criticism, but i prefer to keep it just that. Constructive.

As for the DVD player on the tripples...... BRILLLIANT!!!! Why didnt I think of that......


Now, how to keep all those wires hidden to carry on my clean look :)
 
tone said:
I'm pretty sure if trying to go from 7/8 to 1" on the stock clamps you will be very close to if not into the mounting bolts :-k

check it out before you start mate :)
Click to expand...

I will indeed be cutting it pretty close. Like 1/16" close. But it looks like it will work.

Thanks for the CONSTRUCTIVE CRITICSM. :) (read above for an example of that Trippivot)
 
jmlcolorado said:
As for the DVD player on the tripples...... BRILLLIANT!!!! Why didnt I think of that......
Click to expand...
By the way, the triples or a bag on the fuel tank are about the only place that a DVD player will work. :rolleyes:

Everywhere else has too much vibration and the disk will skip. :D

.
 
that's a considerable stress riser you're creating, if you have only 1/16 aluminum... would that be on the clamps or on the triple tree?
 
midnightcafe said:
that's a considerable stress riser you're creating, if you have only 1/16 aluminum... would that be on the clamps or on the triple tree?
Click to expand...
Thats whats left between the riser bolt and the bar. Its only on the narrowest area of the clamp. The rest of the clamp is still intact.

Threres still plenty to hold very well. The top of the clamp still has well over half an inch so no worries about the bars coming off when riding :)
 
So why not use a 7/8 bar clamped in the triple then cut off and fit an 1" bar you like to that, weld and you're done. should be enough room inside the 7/8 bar for the cables and such, just not the mechanism right?
If I were trying that, I'd slip enough 7/8 tubing inside for a couple of plugwelds as well as the weld at the joint. grind everything round when you're done nicely, then its off to chrome or powdercoat and you've got yourself a custom set of 1" bars that will fit a metric bike with no sacrifice to strength or having to machine a custom top clamp.
 
Sounds fine, as long as you don't find yourself on Laguna Seca or Monster Jam... cut up an aluminum can as a shim to fill the gaps, I doubt you'll get perfect contact using a drill
 
There may be an adaptor available or you could make one from aluminum.
Just bolt onto the top tree and then install your choice of bars. Serves as bar risers, also.

Much safer than having just 1/16" of material.
 
I would look for something from the HD croud, to bolt to the tripple tree. Or something like bar back? ( whatever they are called) adapters used to move bars back that bolt to the 7/8 tripple & allow 1' at the adapter
 
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