Modifying handguard brackets to fit fatbars write up.

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Modifying handguard brackets to fit fatbars write up.

Post  Mauser on Wed Apr 17, 2013 5:28 pm

OK heres what I did to make stock 22mm ~ 7/8" handguard clamps fit my fatbars....gave up trying to find some over here in the UK ready made lol....needed to do this as US headlight comes a lot closer to forks than the UK version and old brackets were a non starter.

Added a couple of nuts between the clamps to hold them at the right size to start with....


I used a step drill like this to make a tapered hole....


Clamped the bracket to a good piece of wood to hold it secure....


Then drilled down to the right size...mine was something like 27.5mm at the fat end.


You end up with a stepped hole as shown.


Next split the 2 halves and wrap some tape around them so you won't mark them whilst doing next steps...


I used a dremel with a course sanding wheel to rough out the steps....


Then used a flap wheel to polish up....


Most of the marks have now gone....


Once your happy with sizes etc line with tape....


Trim excess as shown


Fit and enjoy....not a beer insight


I'm fussy but even I'm impressed how well they fit  razz


Last edited by MAUSER on Thu Aug 21, 2014 9:11 pm; edited 1 time in total

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Re: Modifying handguard brackets to fit fatbars write up.

Post  Focker on Wed Apr 17, 2013 5:44 pm

Mauser wrote:OK heres what I did to make stock 22mm ~ 7/8" handguard clamps fit my fatbars....gave up trying to find some over here in the UK ready made lol....
Looks great and it's more gratifying to fab your own parts anyway. Nice clean work!

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Re: Modifying handguard brackets to fit fatbars write up.

Post  rikco on Thu Apr 18, 2013 8:00 am

good job indeed Bananatool
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Re: Modifying handguard brackets to fit fatbars write up.

Post  AURORA on Thu Apr 18, 2013 1:35 pm

nice
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Re: Modifying handguard brackets to fit fatbars write up.

Post  BuRP on Thu Apr 18, 2013 11:09 pm

Not a beer in sight...



.... and not a cuppa either!


How can you do this to yourself? That's quite a graft, I'd be thirsty a quarter in I tell you!
Good job mate, looks good too.
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Re: Modifying handguard brackets to fit fatbars write up.

Post  Icelander-XR650R on Sat Apr 20, 2013 4:49 pm

Gotta say I'm with BuRP on this one...no beer! doh




Great looking job though, thanks for the write up nice
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Re: Modifying handguard brackets to fit fatbars write up.

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