Handlebars - what is inside?

[gasolina]

Hey guys, been awhile since I've been here. The Bike has been stored for quite awhile while I took care of other things. But now I'm getting her back and doing some mods, starting with new mirrors.




I got a set of Joker Machine Bar End mirrors that look very cool on the bike. These mirrors mount INSIDE the handlebars, requiring removal of the grips for install. Not a problem, grab a set of Kuyrakin Flame grips and do them while I'm at it. So I proceed to pull/cut off the left side grips. When I look inside the handlebar "tube" I see it is not hollow. It looks like there is a piece of aluminum pressed into the bars What is inside our handlebars? How can I get it out?

I need about 2 inches of depth to mount the mirrors, so I figure I just drill them out as deep as I need them. So after 2 drill bit sets and about 2 hours I drilled the pass side bar end. Got the mirror mounted, new grips on, everything is peachy.




So I go to the right side bar end and proceed to drill the solid bar end. On my third drill bit (starting very small with a pilot hole, then going up one size at a time up to 3/4") and all the way at the end of the drilling, the bit breaks off!!! The bits are cobalt bits, the hardest I could find anywhere. There is no way I can drill out this bit, it is broken deep inside the bar end, with nothing sticking out to grab on... Here is a pic after trying at it with one of those stepped drill bits, which just hit the broken off cobalt bit and laughed, would not go anywhere deeper :(





So now I need a new handlebar, and a new set of grips :(

Anyone know what the hell is inside the bars and how to get it out?

[R1convert]

Its a steel plug,there's a couple of plug welds on each end holding them in,i ended up drilling and tapping them to mount my bar end mirrors

[T-Bone©®™]

If ya have to get a new bar, now's the time to upgrade!

http://www.directlineparts.com/produ...d=2630&str=290

[gasolina]

I'm not sure I like the tubular risers, though. I like to the see the machined risers much more now with the tach relocation mod

I wonder if there are any M109Rs out there with different handlebars, not necessarily the tubular ones.

Anyhow, it looks like I'm gonna have to get a new set of bars, regardless :(

[gasolina]

any pics of your mirrors?

Its a steel plug,there's a couple of plug welds on each end holding them in,i ended up drilling and tapping them to mount my bar end mirrors

[Zoom]

I like those mirrors, they are nice and small but out where you can see them.

That plug is just mild steel, but you're going at it the wrong way. Start off with a small bit, something like 1/16" and drill as deep as you need to go, then work up to a larger bit. You will need to go several steps to get there, but it will drill out easily. Big bits don't do well drilling in solid steel, you need the small bit to create the lead hole.

[rynosback]

And drill slow with some oil so you don't burn the bit out.

[RICKTOR]

Those chunks of metal are purposefully put there as a weight to stop handle bar vibration during certain engine RPM. Removing those will make your hands go numb. Looks cool though.

[R1convert]

any pics of your mirrors?

Here's one

[gasolina]

Yep, thats what I've been doing, going up one size at a time. It has been working well. It was one of those small bits that I guess I fatigued when it was as deep as possible, and broke off. I tried the step-ed bit after to see if I could get at the broken bit any better.

I'm wondering if I could drill a second hole, enough for an extractor bit, heat the handlebars with a torch, and twist the plug out... going to give it a try in hopes of saving me the downtime for a new bar.

I like those mirrors, they are nice and small but out where you can see them.

That plug is just mild steel, but you're going at it the wrong way. Start off with a small bit, something like 1/16" and drill as deep as you need to go, then work up to a larger bit. You will need to go several steps to get there, but it will drill out easily. Big bits don't do well drilling in solid steel, you need the small bit to create the lead hole.

[gasolina]

Hopefully the added weight of the mirrors counteract this, and the grips should help a little too... fingers crossed (when I can feel them )

Those chunks of metal are purposefully put there as a weight to stop handle bar vibration during certain engine RPM. Removing those will make your hands go numb. Looks cool though.

[gasolina]

Nice ride! I can see the R1 influences in your bike. I dig the blacked out look, makes the bike look mean as hell! Thanks for the pics

Here's one

[R1convert]

Nice ride! I can see the R1 influences in your bike. I dig the blacked out look, makes the bike look mean as hell! Thanks for the pics

Thanks enjoying the cruiser thing alot more than i thought i would

[Kazimodo]

Gasolina , you are in a jam ..
I have had all kinds of trouble doing work
on cars in the last 30 years , looking at your
situation , what Iwould do is: take small drill bits
and drill holes around your broken drillbit ,
as close as possible to the broken drillbit ,
may need to drill 8-10 holes (maybe more)
to weaken the metal around your broken drillbit ,

Zoom says it is mild steel , so drill slow ,
the most important part of drilling is going slow and
pressing hard , you will see the metal come out
you will know when you are doing it right because
you will progress fast, drill too fast and your drillbit
will overheat ,and you will round the end ,then all you
see is smoke ,your drillbit is no good anymore until
you resharpen it.

Once you have surrounded the broken drillbit with
small holes almost touching each other , try going
with a drillbit 2 or 3 sizes bigger , and go in the new
holes ,if you hear "tac tac tac" stop , your new bit
is touching the broken drillbit ,that can only do more
damage. with angles (drilling from one hole towards
the next hole) and gentle twisting you will take
out as much metal as you can until you can remove the
broken drillbit , by the time you will get it out , you
probably will have mastered the art of drilling , so
you can resume getting the big chunck out to install your
mirror.

Good luck .
DOH ! just noticed this is a 6 days old thread
probably got it done by now..

[Alex_M109R]

Bought some Kuryakyn bar end mirrors and I got to those steel pieces inside the handlebar. Glad I searched before drilling. I thought they were thin pieces, not solid steel.

I won't get into that trouble. I don't know why kuryakyn does not advice about this and place them as " direct fit" for the 109. .

I'll just order the stems and make thed ordinary mirrors.