My custom handlebars

Discussion in 'Touring Models' started by hotrodjohn, Jan 14, 2012.

  1. hotrodjohn

    hotrodjohn Active Member

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    I have tried two sets of bars on my ultra and still have not found what I am looking for. One set of ergo back bars and the Harley pull back bars. I decided to make my own. I cut up a set of stock ultra bars and modified them to where I think I will be comfortable. I ordered some 1 1/4' stock and started making my own bars. I turned down the ends to accept one inch stock bars. I am using the middle part that clamps to the triple tree and the throttle and left handgrip part from stock bars. I am making the part that goes between the two. The first two pictures show the lathe and the adapters I made to fit the one inch pipe. The next one shows the jig I made to get the angles correct and the last is a shot of the bars half done in a vise at about the angle they will be on the bike. The bars will look like they are 1 and 1/4" because you wont see any of the stock one inch bar after the controls are on and the grips.

    Looking at that last picture. I moved the bars down in the vise after that shot. They are not at the riding angle in that picture. Oops.
     

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    Last edited by a moderator: Jan 14, 2012
  2. Slapp

    Slapp Junior Member

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    You gonna powder coat them or chrome them? Put a shot of them up when they are complete and mounted. They look good so far.
     
  3. Iceman24

    Iceman24 Well-Known Member

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    Have tools...will manufacture - great job & perfect way to get the part(s) right. Definitely want to see the finished product.
     
  4. hotrodjohn

    hotrodjohn Active Member

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    I think I will powder coat. I have the option to further alter them if needed and then they could be re coated pretty easily.
    [​IMG]
     
  5. TripleJ

    TripleJ Senior Member

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    +1, always like seeing the finished product :)
     
  6. hotrodjohn

    hotrodjohn Active Member

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    Here are a few more pics. The first one shows jiging up to cut the compound angle. Was a lot easier in the jig with a 4.5" angle grinder with a cut off wheel than to use my saw. The second is the jig for the easy angle on the bottom of the bars and the third is another vise shot. Heading out to the garage (heated,its 15 degrees out brrr) to finish them up and hopefully get them to the coater theis week:D:D
     

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  7. hotrodjohn

    hotrodjohn Active Member

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    Well all to be done now is to see if they fit! Few more pics. The final assembly jig and look they even lay flat.:D
     

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  8. TripleJ

    TripleJ Senior Member

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    Those are going to look sharp.
     
  9. hotrodjohn

    hotrodjohn Active Member

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    Mounted on the bike:D
     

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  10. Iceman24

    Iceman24 Well-Known Member

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    Kudos to you, sir - awesome job!!! Can't wait to see them coated & permantely mounted. This might be a "profitable" hobby...???