Handle bar end weights GL1500

2885 Views 7 Replies 5 Participants Last post by Kimswang, Mar 7, 2011

waggawing

Discussion Starter · Mar 5, 2011

imported post

Guys,

Can anyone tell me if the plugs in the ends of the handlebars on the 1500's can be removed. I want to fit some custom bar ends that need to slide into the end of the handlebar. How long are the weight plugs and do they need to be drilled out.

Thanks

Save

Status: Not open for further replies.

1 - 8 of 8 Posts

agnogel

· #2 · Mar 5, 2011

imported post

Hi David the ends are pressed welded in i dont know any one who did what you are looking for can you post a pic of the new ends i made up my own with eagle head bolts were i drilled and taped the ends to accept them

See less See more

Save

GWNorman

· #3 · Mar 5, 2011

imported post

New addition to the family Peter?

Save

agnogel

· #4 · Mar 5, 2011

imported post

No same guy in the avatar its the only photo of the grips i have

Save

waggawing

Discussion Starter · #5 · Mar 6, 2011

imported post

Thanks Pete,
I was thinking about it overnight and came to the same solution as you. Drilling and tapping the handlebar may turn out to be the best solution anyway.

Save

agnogel

· #6 · Mar 6, 2011

imported post

if you are going my way when you drill the cap on the trottle sidemake the hole a little bigger so the trottle will rotate and not snag the grip put a little locktight on the treads and leave the head a little slack from the grip i put a washer on mine just to help

Save

ob1jeeper

· #7 · Mar 7, 2011

imported post

Yes the bar weights can be removed. And no they are not welded in to any significant degree.

That said... Depending on how much room you need, you may be able to simply drive them in an inch or so with a hammer and a punch... After reading the below, you will understand why that may be possible...

OR... You can do what I did and remove these weights...

I've done two bar sets, and have found it's pretty easy, provided you take care with the alignment while drilling and tapping.

Just finished doing this, as part of another project which I will be posting about as soon as I finish.

Here is how I remove the weights.
Note: that while some of these pictures were taken with a junkyard bar I bought for practice and to see if this could be easily done, doing so on the bike is no biggie, as long as you are careful with the alignment of the drill, and take care with the tap, so that you do not break it off in the weight.

First center punch the weight to get the drill centered.

Next using a pilot size drill (I used 1/8") carefully align the drill and drill a hole approx 1.5-2" deep into the weight, followed by a 5/16" drill, drill the weight to the same depth of the pilot hole.

Then drill using a 3/8" drill, to approx 3/4-1" deep... This is for ensuring alignment of the tap you will use in the next step.

Then using a 3/8-16 tap, cut approximately 5-6 threads (5/16-3/8" deep) into the weight. Be careful with this step and use proper cutting oils, so you do not break the tap off in the hole.

Finally I used a small slide hammer consisting of an approximate 12" long grade 5 or better 3/8-16 bolt and an approx 10-12 oz weight to remove the weights. Takes about 4-5 sharp whacks, and the weight will be slide right out, as the only weld is a small (less than 1/4" dia) resistance weld, as you can see in the pictures...