Removing handlebar mounts on top clamp

[xb33bsa]

;D

 

[spotty]

OR.......cut threads into the outside of the top of the forktubes and corresponding ones into the blind recesses under the top clamp. that way the tubes screw into the underneath of the clamp which holds them as well as any other method and then obviously they're held by the bottom clamp to stop them unscrewing.

this method has been used in the chopper world for a long long time where billet clamps have been the go for as long as billet has been around.

 

[warpt_99]

sorry for the delay, I finished this last weekend. I still feel that I can round it out more with my limited tools but I fear going too far and messing up.

 

[18Bravo]

It looks good as is, but if you want to work it some more, don't worry about going too far. That's how we improve our skills. If you screw it up, you throw some weld on it, or buy another one and start over.
I do understand your apprehension though. I remember the first time I took a cutting wheel to some $1500 billet wheels...

 

[jpmobius]

Maybe the underside will give an indication of how much material you can remove. The shape of the underside may not be what you expect based on looking at the top, especially after removing some of the material, so let the underside help guide your decisions. I wouldn't be too concerned about the existing bar mount holes, whether you plan to weld them up or not. Looks like you have the bulk of material taken off. I like a die grinder and a double cut rotary file for contouring things like this. Hand files are about as fast, and make straighter surfaces, but are sometimes a bit hard to get into some of the inside curves. Put wax (or bar soap if you don't have any wax) on the cutter and it won't clog with aluminum. Any kind of grinding stones are usually pretty tough for aluminum due to clogging.

 

[xb33bsa]

wax ? what are you crazy ;D next you will be suggesting they use a golf ball for a handle on da file

 

[warpt_99]

I think I'm going to leave it as is and sand down the the remaining gouges. I'm not going to fill in the holes because I was contemplating installing switches, push buttons, LED lights, etc inside them for the various controls or displays like head lights, kill switch etc

 

[surffly]

What is your actual goal?
If the stumbling block is cutting off a tab, methinks you might be walking into some other traps with your "mods"