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Basically, I'm considering a little mod project, but I need to be able run wires through the handle bars. Rather than cable ties along the length of the bar I was hoping to be able to drill small holes at the centre section of the bar and perhaps a small hole at the end.
On an alu bar used on a commuter bike, do you think that would compromise the structural integrity of the bar too much or would it be ok?
Where would be the best place to drill? Just to the e side of the clamp, or a little out from it... Or what about a hole through the clamp itself into the bar as well .?
Or am I going to die . . . . Horribly
🙂
drill it and not to near the clamp as that would be the most likely snap spot
Drilling holes in a stressed aluminum tube = Fireball of Death. HTH 🙂
Or am I going to die . . . . Horribly
but at least we would all learn from it.
Quite common on motorcycles. Go for it.
buy a steel handle bar and drill that
If you are going to drill holes, then surely as far from the centre of the bar the better, no?
But the further from the centre, the more pointless having the wire inside would be.
It is a commuter, so I wonder how much stress margin I would be using up by drilling a hole . . .
drill on underside of bar and all will be ok.... probably
Right in the middle, through the stem faceplace. Certainly not just outside the clamp. All IMHO, etc...
Can you drop me a PM with your full name, date of birth, medical history, etc. I'd like to take out some life cover on you 😉
whats the project, led's directly in the bar?
I'd go for a hole through the clamp and bars right in the middle. Assuming the clamp's man enough, the bars will be supported either side of the hole by the stem. A hole near the end shouldn't be a problem. Check for cracks before every ride for a few weeks.
I agree with nick(s) - if you're going to drill near the middle, then the least stressed point is right in the middle inside the stem clamp.
Pretty common on old road bars to allow for concealed brake cables.
On my new TT bar, the extensiosn have holes in them for concealed gear cables
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Where does the spoon come in?
Make sure the hole is nice and smooth - more stress in a corner etc
other than shortening the bars, any other modifications which require removing material would seriously reduce the structural integrity of the bars and could lead to failure. Comes down to your use of said drilled bars? if its for off road roading then i wouldn't but if its say for a commuter i wouldn't see it being too much of a danger.
whats the project, led's directly in the bar?
pretty much ... i want to have little white lights in the front of the bar-ends and red ones to the rear. I'm not talking about being able to see by them or anything, just so that they can be seen. It would be enough to think from a distance " whats that? " which would mean they've at least seen me.
Also would create a wider visual presence than a single light in the middle.
On a homebrew setup, I could then run the lights off the main battery.
You can get tiny led lights to put on your dog's collar. They just have a little watch/calculator battery in them and are about the size of a schraeder valve cap. Just use those - self contained, no wires?
I would put the hole in the bottom of the bar, or the front face.
I would not put the hole bang in the middle as I don't think this is the least stressed area.
I would put the hole 10 mm from the edge of where the stem clamp is.
The biggest stressed area is right next to where the bar enters the stem.
Not a material scientist though, just an amateur who has learnt how not to break stuff too often!
I know the dog collar lights you mean, I even have some similar things, but ultimately, they need daft wee batteries. I already have big batteries for the main lights so why not use them.
It's daft wee batteries vs daft extra wiring, holes in handlebars, splicing power wires onto your batteries...I know the dog collar lights you mean, I even have some similar things, but ultimately, they need daft wee batteries. I already have big batteries for the main lights so why not use them.