Drilling Clubmans?

[danmpls]

I have a set of bikemaster clubmans but was told only to drill them out for the control set screws and not to pull wiring through them. Anyone else heard anything like that?

 

[Skyeye]

Re: Clubmans

I pulled the wires through mine, one wire at a time. I don't see a problem but you have to be very careful not to chafe the wire going around the sharp corners.

Scott

 

[danmpls]

Re: Clubmans

The fishing part (wire pulling) doesn't bother me. I think the concern was drilling more holes in the bars.

 

[Swagger]

Re: Clubmans

If they are thin wall any hole you drill may weaken them. I've had OEM bars flex and collapse around holes drilled....
I'm against the practice myself

 

[danmpls]

Re: Clubmans

The bars i am removing have a sleeve over the the middle, where the factory holes are drilled. I am guessing if I weld some extra support the should be ok, right?

 

[Swagger]

Re: Clubmans

No way in hell I'd do it. Not only will it be heavy but you can weaken the bars with heat unless you're a good welder.
Seriously, notch out your switch gear so the wires can be run externally, route them clean and tie wrap them...

 

[450cl]

Try using vasoline if you decide to run them internally. There is a type electricians use, dont know the brand name.

 

[slushie07]

I pulled the wires through mine and had to drill a hole for each the left and right controls and then a bigger hole in the middle for both sets of wires to come out. Structurally I would not worry, and make sure to wrap the wires as tight as possible with electrical tape and then lube them up and run them through. You can attach a small nut to a strong string or thread and then send that through from the control holes to the center holes then wrap the thread to the wires and tape it up well. Then just slowly pull them through. You might want to get grommets for the holes or smooth them out so they don't fray the wires and cause a short.

 

[danmpls]

I am actually an electrician, so the wire pulling part is not a problem. There are several brands of pulling compound, yellow 77, polywater etc.
One very helpful trick when pulling cable is in making the "head". This is how you attach the pulling string to the wires. Using a half hitch knot and staggering the end of the wires you're pulling is key. I think I will just post some picks when I get to this point.
My main concern was in the actual drilling of the bars. I was told it would compromise the integrity of the bars and they may fail. Reality being that, anything can fail. Needless to say I will be drilling some holes.