How to make a folding bar end cap key
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Thread: How to make a folding bar end cap key

  1. #1
    Very Active Member avago's Avatar
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    Default How to make a folding bar end cap key

    For those of us that like the look of having a key in a bar end cap but find that it sticks in to everything when in your pocket, here is an alternative option.
    Here's what you need.
    Click image for larger version. 

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    Put the key in your ignition and press it in and turn to the park position and mark the key.
    Measure the depth of the hollow inside the end cap and mark the key to where you will cut it off.
    Put a dot in 45 degrees from a corner. this is where it will pivot.
    Cut the key and round the outer corners.
    Drill a hole big enough for your pivot shaft to fit through. I am using a small nail which I have cut down.
    Click image for larger version. 

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    Cut a slot in the cap to hold your pivot shaft and check for positioning.
    Click image for larger version. 

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    Cut the slot to the side to hold the key when folded down.
    Click image for larger version. 

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    Glue in the ends of the pivot shaft first. When dry test that it moves as expected.
    When satisfied, put something in behind the key to make the slot when the glue is poured in.
    I used some cardboard and used a barrier cream over it and the key to stop the glue sticking to it.
    You can use vaseline or anything else really to stop the glue sticking.
    Click image for larger version. 

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    A man would be more interested in a womans mind if it bounced gently as she walked.

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  3. #2
    Very Active Member avago's Avatar
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    Default Part two

    Pour in your glue and wait for it to set. Remove the cardboard and wipe out the slot.
    It should now look something like this.
    Click image for larger version. 

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    The right hand one is my original fixed key.
    So there you have it. Hope its useful and may you get no more holes in ya pockets!.
    A man would be more interested in a womans mind if it bounced gently as she walked.

  4. #3
    Very Active Member SKIDMARK's Avatar
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    Default

    Quote Originally Posted by avago View Post
    Pour in your glue and wait for it to set. Remove the cardboard and wipe out the slot.
    It should now look something like this.
    Click image for larger version. 

Name:	IMG_5763.jpg 
Views:	284 
Size:	33.1 KB 
ID:	321649
    The right hand one is my original fixed key.
    So there you have it. Hope its useful and may you get no more holes in ya pockets!.

    Nice lil mod there, Great thinking.

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  6. #4
    Very Active Member M109Dreamer's Avatar
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    Very cool. Thats the main reason I dont use mine, jabs me in the leg all the time.

    Sent from my SAMSUNG-SM-G920A using Tapatalk

  7. #5
    Very Active Member avago's Avatar
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    Quote Originally Posted by M109Dreamer View Post
    Very cool. Thats the main reason I dont use mine, jabs me in the leg all the time.

    Sent from my SAMSUNG-SM-G920A using Tapatalk
    Man I hear ya! Put up with the fixed one for two years and it constantly niggled me. Looks good but a right pita! Haha


    Sent from my portable microwave emitter
    A man would be more interested in a womans mind if it bounced gently as she walked.

  8. #6
    Very Active Member OGPAULG's Avatar
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    great mod for the mod
    .
    One who leads with no followers is merely taking a walk

  9. #7
    Very Active Member shrk352's Avatar
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    Quote Originally Posted by M109Dreamer View Post
    Very cool. Thats the main reason I dont use mine, jabs me in the leg all the time.

    Sent from my SAMSUNG-SM-G920A using Tapatalk

    I keep a normal thin key on my keychain, If I don't want to carry the chrome cap around I just lock it under the seat. It stays in the bike 90% of the time though.

  10. #8
    Active Member Luap's Avatar
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    Quote Originally Posted by avago View Post
    Pour in your glue and wait for it to set. Remove the cardboard and wipe out the slot.
    It should now look something like this.
    Click image for larger version. 

Name:	IMG_5763.jpg 
Views:	284 
Size:	33.1 KB 
ID:	321649
    The right hand one is my original fixed key.
    So there you have it. Hope its useful and may you get no more holes in ya pockets!.
    Nice mod. I just did mine with the bar end but without the pivot... THEN I found this thread lol
    Well, I still have other bar end, and another key is only $10 at the dealer :)
    2019 M109R B.O.S.S. red/black
    MODS: LED signals, Integrated tail light, Luap hole-saw mod, axle mounted plate, no beaver, carbon fiber look tank bra, dual air horn, black spiked grips, "bar end key" mod, drink holder :), more to come

  11. #9
    Active Member Luap's Avatar
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    Quote Originally Posted by shrk352 View Post
    I keep a normal thin key on my keychain, If I don't want to carry the chrome cap around I just lock it under the seat. It stays in the bike 90% of the time though.
    That was my thinking.
    Most places I go I don't feel like anyone is going to ride off on my bike, and at night it's locked in the garage
    2019 M109R B.O.S.S. red/black
    MODS: LED signals, Integrated tail light, Luap hole-saw mod, axle mounted plate, no beaver, carbon fiber look tank bra, dual air horn, black spiked grips, "bar end key" mod, drink holder :), more to come

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