Topic: Modifed SERG Handlebars (Read 16834 times)

FUZZNUTS · « **on:** August 06, 2010, 08:07:36 PM »

The beginning, asked around the site and got two sets of SERG handlebars. With the intention of modifying to add 2" to hieght and 2" more to the pullback. Here are some pic's documenting the work.

FUZZNUTS · « **Reply #1 on:** August 06, 2010, 08:08:52 PM »

I made the cuts with a tubing cutter.

FUZZNUTS · « **Reply #2 on:** August 06, 2010, 08:10:02 PM »

More,

FUZZNUTS · « **Reply #3 on:** August 06, 2010, 08:13:00 PM »

The stock height of the pullback when laying flat on the table was 3 1/4 on one side and 3 1/2 on the other. Both sets of bars were the same.

FUZZNUTS · « **Reply #4 on:** August 06, 2010, 08:16:44 PM »

The results after cutting both of the bars and prior to welding and drilling out the handles for Heat Demons.

FUZZNUTS · « **Reply #5 on:** August 06, 2010, 08:18:57 PM »

SE-Dave gave me a hand during the fabrication and drilling.

FUZZNUTS · « **Reply #6 on:** August 06, 2010, 08:25:25 PM »

After the drilling we set up the bars on a couple of home made jigs and got it ready for welding. As you can see the height of the pullback is now 2" further back. For a total of 5 1/2 ".

FUZZNUTS · « **Reply #7 on:** August 06, 2010, 08:29:14 PM »

Another of the jig.

FUZZNUTS · « **Reply #8 on:** August 06, 2010, 08:31:24 PM »

Yours truly making the pretty blue light.

FUZZNUTS · « **Reply #9 on:** August 06, 2010, 08:35:20 PM »

I know, I know, it's not a thing of beauty. But it will hold and it's yet to be buffed.

FUZZNUTS · « **Reply #10 on:** August 06, 2010, 08:37:42 PM »

Looks a little different

FUZZNUTS · « **Reply #11 on:** August 06, 2010, 08:39:22 PM »

After the buffing.

FUZZNUTS · « **Reply #12 on:** August 06, 2010, 08:47:52 PM »

I brought the bars home and will snap a few pics with them resting against the exsisting ones on my bike. But anyway these are just templates so I can take these to a Fabrication shop and they can twist me up a few. We, at work do not have the mandrels and other tube bending equipment to fab up what I want and I know what a few other SERG riders want. Stay tuned..................................Fuzz

TN · « **Reply #13 on:** August 07, 2010, 12:21:30 AM »

good idea. keeping my eye on this.

whats the altered bar measurements?

you purge during the weld process?

TN

Beemer · « **Reply #14 on:** August 07, 2010, 10:55:40 AM »

That is EXACTLY what I've wanted!

Finally went with the WO517s that pull back a little too far.

I did notice though that in the pictures of the 11 SEURG that those bars look higher with slightly more pull back than our stock SERG. I hope you're not doing all this just to duplicate the 11s

FUZZNUTS · « **Reply #15 on:** August 07, 2010, 01:17:51 PM »

Quote from: 61bbltop on August 07, 2010, 10:55:40 AM

That is EXACTLY what I've wanted! Finally went with the WO517s that pull back a little too far.

I did notice though that in the pictures of the 11 SEURG that those bars look higher with slightly more pull back than our stock SERG. I hope you're not doing all this just to duplicate the 11s

Have'nt seen the 2011s yet. I'll have to look and take my tape measure with me. Just want to keep the same look as the stock and 2"higher and 2 more inches in the pullback.

FUZZNUTS · « **Reply #16 on:** August 07, 2010, 01:20:04 PM »

Quote from: TN on August 07, 2010, 12:21:30 AM

good idea. keeping my eye on this. whats the altered bar measurements?

you purge during the weld process?

TN

No, I did not purge. I'm not worried about Xray. These are just a template.

TN · « **Reply #17 on:** August 07, 2010, 10:01:26 PM »

Quote from: FUZZNUTS on August 07, 2010, 01:20:04 PM

No, I did not purge. I'm not worried about Xray. These are just a template.

hell Rich, i luv yer work here.

i'm just a anal welder and think if you liked those, a chrome job would complete it. i been trying to figure out a 2" rise and you got it.

not gonna ask you what kinda filler metal you used.

TN

Cvostu · « **Reply #18 on:** August 07, 2010, 10:46:38 PM »

i'll ask

FUZZNUTS · « **Reply #19 on:** August 08, 2010, 09:24:13 AM »

Quote from: TN on August 07, 2010, 10:01:26 PM

hell Rich, i luv yer work here. i'm just a anal welder and think if you liked those, a chrome job would complete it. i been trying to figure out a 2" rise and you got it.

not gonna ask you what kinda filler metal you used.

TN

Phil, Just mild steel. 1/16

Highwaystar · « **Reply #20 on:** August 08, 2010, 11:50:06 AM »

Butt welding can be a problem when ground back. penetration is paramount. the chrome process adds a hardening factor. I would not recommend this for the average home fabricator. a thin insert with a few tig plug welds would eliminate the good chance of the weld failing. Good Idea ...just adding caution to someone with a mig welder at home who would pick up on this.

Beemer · « **Reply #21 on:** August 08, 2010, 06:05:43 PM »

I'll piggyback on Highway's warning. To make such grafting workable he's right, you'd have to add an internal (or external) sleeve for strength. Once done, you'd find it nearly impossible to rout the wires internally. Externally, you could run the wires but it wouldn't look clean.

Can't wait to see the finished product!

FUZZNUTS · « **Reply #22 on:** August 08, 2010, 08:49:00 PM »

Quote from: Highwaystar on August 08, 2010, 11:50:06 AM

Butt welding can be a problem when ground back. penetration is paramount. the chrome process adds a hardening factor. I would not recommend this for the average home fabricator. a thin insert with a few tig plug welds would eliminate the good chance of the weld failing. Good Idea ...just adding caution to someone with a mig welder at home who would pick up on this.

Like I said, this is only a template...............................................Fuzz

Twolanerider · « **Reply #23 on:** August 08, 2010, 11:55:52 PM »

Quote from: FUZZNUTS on August 08, 2010, 08:49:00 PM

Like I said, this is only a template...............................................Fuzz

Hey Rich, you think that weld is going to hold? You know, in service. It'd look better chromed too. When are you gonna do that?

FUZZNUTS · « **Reply #24 on:** August 09, 2010, 07:01:04 AM »

Quote from: Twolanerider on August 08, 2010, 11:55:52 PM

Hey Rich, you think that weld is going to hold? You know, in service. It'd look better chromed too. When are you gonna do that?

Don, I was hoping to get this to a fabricator to have them twist me up a pair or two. And spend the money on them to be chromed. I'm not chroming the template, although I have considered it. But when I hand the template over it's exactly what I want replicated. I have'nt lined up a handlebar fabricator yet. I'm kinda flyin by the seat of my pants so to say. But I do know what I want. And what a few others want also. And since there was no one out there to give me what I wanted , I took the bull by the horns so to speak..........................Fuzz

Twolanerider · « **Reply #25 on:** August 09, 2010, 11:16:50 AM »

Quote from: FUZZNUTS on August 09, 2010, 07:01:04 AM

Don, I was hoping to get this to a fabricator to have them twist me up a pair or two. And spend the money on them to be chromed. I'm not chroming the template, although I have considered it. But when I hand the template over it's exactly what I want replicated. I have'nt lined up a handlebar fabricator yet. I'm kinda flyin by the seat of my pants so to say. But I do know what I want. And what a few others want also. And since there was no one out there to give me what I wanted , I took the bull by the horns so to speak..........................Fuzz

Sorry Rich, that question was my stupid attempt to be stupid. Since you'd been asked so many times already questions that were all explained in the beginning by saying "it's a template" I was being an ass and asking the same thing again as a poor attempt at wondering just how many more times you'd be asked.

FUZZNUTS · « **Reply #26 on:** August 09, 2010, 11:25:19 AM »

Gotcha, Don.

jfh · « **Reply #27 on:** August 09, 2010, 07:31:05 PM »

Hey Rich,

I'm the guy that met you on the NJTP to drop a set of bars off. Now I know what you were up to. Hope they work out for you. Nice job and a lot of work, but at least they will be exactly to you specifications.

Regards,
John

FUZZNUTS · « **Reply #28 on:** August 15, 2010, 02:12:41 PM »

Quote from: 61bbltop on August 07, 2010, 10:55:40 AM

That is EXACTLY what I've wanted! Finally went with the WO517s that pull back a little too far.

I did notice though that in the pictures of the 11 SEURG that those bars look higher with slightly more pull back than our stock SERG. I hope you're not doing all this just to duplicate the 11s

Update..........................The 2011s handlebars are basically the same hieght but more pull back than the 09 SERG. I measured the 11s handle bars on the show room floor. And basically for hieght from the bottom 90 to the top 90 and it's 9 1/2 inches on the 11s bar. And the bars I modified from the same points measure 11 1/2". I have'nt got a chance to take a pic side by side with my bike because it's been at the dealers since last Wed. I thought that I was having issues with the compression relief but it turns out it's a starter problem. So hopefully I'll be getting the bike back by Tues night. I gottta leave for Fayetteville W.V. Wed morn.............................................Fuzz

Beemer · « **Reply #29 on:** August 15, 2010, 09:09:57 PM »

Then your bars should be better in that if you want them closer, all you'd have to do is roll them back a bit.

Have you found a fab shop yet?

Highwaystar · « **Reply #30 on:** August 15, 2010, 10:12:09 PM »

I guess the little caution flag worked. It is very clear to every one now that you were fabricating a test set. Any chassis race car fab shop with a mandrel type bender can pop out a set easily. Nice job with the mock up FUZZ.

FUZZNUTS · « **Reply #31 on:** August 16, 2010, 07:36:23 AM »

Quote from: 61bbltop on August 15, 2010, 09:09:57 PM

Then your bars should be better in that if you want them closer, all you'd have to do is roll them back a bit.

Have you found a fab shop yet?

I sent a email to Flanders out in California, and I got a responce back from them. Looks like I have to wait until the 24th to hear from Mr Flanders himself. I do have a local guy here but he's not a productin based outfit. I have lots of time to find someone. ................................................Fuzz

Texas 103 · « **Reply #32 on:** August 19, 2010, 11:08:56 PM »

Quote from: FUZZNUTS on August 15, 2010, 02:12:41 PM

Update..........................The 2011s handlebars are basically the same hieght but more pull back than the 09 SERG. I measured the 11s handle bars on the show room floor. And basically for hieght from the bottom 90 to the top 90 and it's 9 1/2 inches on the 11s bar. And the bars I modified from the same points measure 11 1/2". I have'nt got a chance to take a pic side by side with my bike because it's been at the dealers since last Wed. I thought that I was having issues with the compression relief but it turns out it's a starter problem. So hopefully I'll be getting the bike back by Tues night. I gottta leave for Fayetteville W.V. Wed morn.............................................Fuzz

Get them to upgrade your comp Rich...Hard starting & kick back, they will warranty an S.E comp, they just can;t call it that..I will be nice and quiet....

cmecatchu2 · « **Reply #33 on:** August 28, 2010, 12:55:37 AM »

Texas 103--

what do you mean by hard starting and kick back on the SERG?

NVWLDTHG · « **Reply #34 on:** August 29, 2010, 12:13:41 AM »

I can't believe I went to the other Road Glide blog to find pictures of the new bars. And, then I got sidetracked looking at windshield pictures.

FUZZNUTS · « **Reply #35 on:** November 15, 2010, 11:35:52 AM »

Finally, got the new handlebars fabbed. They'll be chromed this week , installed next week. I'll post some of the pre chrome pics later on tonight. .........................Fuzz

FUZZNUTS · « **Reply #36 on:** November 15, 2010, 04:45:46 PM »

FUZZNUTS · « **Reply #37 on:** November 15, 2010, 04:46:35 PM »

FUZZNUTS · « **Reply #38 on:** November 15, 2010, 04:47:17 PM »

FUZZNUTS · « **Reply #39 on:** November 15, 2010, 04:49:07 PM »

last, they'll be chromed this week and I should have them installed next week sometime.

cmecatchu2 · « **Reply #40 on:** November 17, 2010, 11:44:10 AM »

Looks great, can't wait to see them installed and what you think. Who did the work for you?

LETS_ROLL · « **Reply #41 on:** November 17, 2010, 10:03:23 PM »

Looking good. Let's Roll

FUZZNUTS · « **Reply #42 on:** November 18, 2010, 10:23:01 AM »

Quote from: cmecatchu2 on November 17, 2010, 11:44:10 AM

Looks great, can't wait to see them installed and what you think. Who did the work for you?

I don't have them in my hand yet. The bars are getting chromed as I speak. I have left my template with the vendor. If anyone wants to replicate them again, all they have to do is get a hold of this gentleman. Bill Rickards. I'll post his website. Once I get the new bars back in my hand I will take a couple of pics side by side with the OEM's and my new and improved and a couple of pics with the improved hand and arm position after installation. Then if anyone likes what they see, then you can put a order in with Bill. GH turned me on to this guy. He's located in New york State. It will be a week or two before I can get any more pics................................................................................Fuzz

http://www.brcustomcycles.com/MEASURING_NEW_BARS_UP.php

LETS_ROLL · « **Reply #43 on:** November 18, 2010, 12:24:35 PM »

Can't wait that might be the ticket for a few of us here. Let's Roll

GregKhougaz · « **Reply #44 on:** November 18, 2010, 01:04:56 PM »

Looks great Fuzz! Looking forward to seeing the final version.

Hotrod50 · « **Reply #45 on:** November 23, 2010, 05:59:19 PM »

Quote from: FUZZNUTS on November 15, 2010, 04:45:46 PM

1st

These don't look much taller?

09S/E roadglide · « **Reply #46 on:** November 23, 2010, 09:18:43 PM »

FUZZNUTS · « **Reply #47 on:** November 24, 2010, 08:57:29 AM »

Quote from: hotrod50 on November 23, 2010, 05:59:19 PM

These don't look much taller?

Thats because your not looking at the OEMs. The Pic your looking at is the Mock up and the newly fabbed bars fashioned to look like the mock up. I will post a pic of the difference when I get all my parts in the same state at one time. Vendor just sent me a pic of the new bars chromed. I should have them home real soon. But, Hotrod you gotta read the whole thread!!!!!!!!!!!!!!!!!!!.............................................Fuzz

Hotrod50 · « **Reply #48 on:** November 24, 2010, 05:24:33 PM »

Sorry. Didn't catch it anywhere.

FUZZNUTS · « **Reply #49 on:** November 25, 2010, 08:07:13 AM »

Quote from: hotrod50 on November 24, 2010, 05:24:33 PM

Sorry. Didn't catch it anywhere.

Ok, Stay tuned.

FUZZNUTS · « **Reply #50 on:** December 01, 2010, 06:37:33 PM »

The next pics will be the bars actually mounted. But at least you can see the difference between the OEM and the new bars.

FUZZNUTS · « **Reply #51 on:** December 01, 2010, 06:38:12 PM »

FUZZNUTS · « **Reply #52 on:** December 01, 2010, 06:38:50 PM »

FUZZNUTS · « **Reply #53 on:** December 01, 2010, 06:39:36 PM »

FUZZNUTS · « **Reply #54 on:** December 01, 2010, 06:40:21 PM »

Last one.

FUZZNUTS · « **Reply #55 on:** December 01, 2010, 06:48:27 PM »

The new grips are ready to accept Heat Demons, I still have to purchace the chrome GPS mount. I should have them mounted buy around Christmas. .............................................................................................Fuzz

hdbrad03 · « **Reply #56 on:** December 01, 2010, 08:44:42 PM »

OK I'll Bite! How do we order the Bars and where do we send to have them chromed? So the bars come from the Vendor with and inside diameter of 7/8"?

They look great!

Brad

09S/E roadglide · « **Reply #57 on:** December 02, 2010, 07:20:33 AM »

nice job FUZZ

FUZZNUTS · « **Reply #58 on:** December 02, 2010, 08:29:17 AM »

Quote from: hdbrad03 on December 01, 2010, 08:44:42 PM

OK I'll Bite! How do we order the Bars and where do we send to have them chromed? So the bars come from the Vendor with and inside diameter of 7/8"?

They look great!

Brad

PM Sent..........................................

FUZZNUTS · « **Reply #59 on:** February 22, 2011, 07:37:46 PM »

Finally, I have gotten the handle bars installed. Here's a few pics...................................Here's before.

FUZZNUTS · « **Reply #60 on:** February 22, 2011, 07:39:14 PM »

Here's after.

FUZZNUTS · « **Reply #61 on:** February 22, 2011, 07:40:20 PM »

Front shot before.

FUZZNUTS · « **Reply #62 on:** February 22, 2011, 07:41:10 PM »

Front shot after.

FUZZNUTS · « **Reply #63 on:** February 22, 2011, 07:42:13 PM »

Other side before.

FUZZNUTS · « **Reply #64 on:** February 22, 2011, 07:43:11 PM »

Other side after.

FUZZNUTS · « **Reply #65 on:** February 22, 2011, 07:44:37 PM »

As you can see , they are much more comfortable for the long haul rides.

FUZZNUTS · « **Reply #66 on:** February 22, 2011, 07:51:25 PM »

I did have to drill out the throttle side for the Heat Demons. When I first started this little project Iwas under the impression that the handle bar manufacture would do this for me. But he did not. Also the bars at the point where the glove boxes open, they are a little wider. The extra meat from the 1 1/4 bars prevent the glove boxes from fully opening while your riding.

FNGw/08SERK · « **Reply #67 on:** February 22, 2011, 08:04:20 PM »

Thanks for posting the pics Rich. Have you got any miles on em yet or are you snowed in like I am??

FUZZNUTS · « **Reply #68 on:** February 22, 2011, 08:20:43 PM »

Had some snow this AM. Next 50 deg day I'll get out and do a few miles.

gordy · « **Reply #69 on:** February 22, 2011, 10:36:47 PM »

This is the pair I made. 1.25" radius bent with tapered ends. Only problem was mounting the 1.25 handlebar clamp.

TN · « **Reply #70 on:** February 23, 2011, 09:38:14 AM »

Quote from: FUZZNUTS on February 22, 2011, 07:39:14 PM

Here's after.

looks good Rich.

got my attention, are these available? price?

come on down south and start yer riding season early, spring is here. pollen count is high.

TN

FUZZNUTS · « **Reply #71 on:** February 23, 2011, 10:06:07 AM »

PM Sent..........................................................Fuzz

cmecatchu2 · « **Reply #72 on:** February 23, 2011, 04:39:16 PM »

Rich,

they look great and what I am looking for to help on the long trips-- Great Job! Thanks

SilvrBulet · « **Reply #73 on:** February 24, 2011, 08:37:09 AM »

Fuzz, looks great. It is commendable that you took this on and saw it through. I have the Yaffe 10" on my recently acquired SERG3. I really like the look of them but when I replaced the CV windshield with a taller CV (probably 2.5" higher), I ran into problems with the bars hitting the shield at full lock. I moved the Yaffe's back about 1/2" and adjusted my controls to compensate but I am not satisfied yet with where I had to leave the controls to make it work. I will probably have the CV trimmed to give me back some space. I see your windshield is pretty tall too, have you run in to any problems like that yourself? No doubt the dramatic cut of the Yaffe's are contributing to my situation. Thanks very much for the comprehensive view of your project. Cheers, Silvr

aclass · « **Reply #74 on:** February 24, 2011, 06:27:44 PM »

Quote from: SilvrBulet on February 24, 2011, 08:37:09 AM

I replaced the CV windshield with a taller CV (probably 2.5" higher),

What CV did you have before the taller one just put on Fuzz? I have the GT Small and am fixin to install 12" monkey bars. I'm worried about them hitting.

SilvrBulet · « **Reply #75 on:** February 24, 2011, 06:47:55 PM »

Aclass,

The bike had the GT-small installed but JFH had cut it an 1" to 1.5" to improve his line of sight. I bought the GT-small again but it still wasn't tall enough to keep the wind out of my eyes so I sent it back and bought the GT stock height. That's when the problem showed up. Perhaps Mark at Clearview can help you make some measurements to avoid the problem. As I mentioned earlier, I will probably have mine trimmed to fix the problem.

Also note Aclass that this is Silvr Bulet and not Fuzz and that I'm talking about the Yaffe bars not what Fuzz has created. He hasn't weighed in yet on if he's seen a problem.

Hope this helps and good luck,

Silvr

FUZZNUTS · « **Reply #76 on:** February 25, 2011, 07:18:23 AM »

Quote from: SilvrBulet on February 24, 2011, 08:37:09 AM

Fuzz, looks great. It is commendable that you took this on and saw it through. I have the Yaffe 10" on my recently acquired SERG3. I really like the look of them but when I replaced the CV windshield with a taller CV (probably 2.5" higher), I ran into problems with the bars hitting the shield at full lock. I moved the Yaffe's back about 1/2" and adjusted my controls to compensate but I am not satisfied yet with where I had to leave the controls to make it work. I will probably have the CV trimmed to give me back some space. I see your windshield is pretty tall too, have you run in to any problems like that yourself? No doubt the dramatic cut of the Yaffe's are contributing to my situation. Thanks very much for the comprehensive view of your project. Cheers, Silvr

SilvrBulet, I have the tallest C.V. that you can buy. XXL, I also cut an 1 1/2 off the top of the wind shield. (while on the bike) The C.V. is now at the bottom of my nose. I hate looking thru a windshield. However my bars do not hit my shield at full lock. Not even close............................Fuzz

SilvrBulet · « **Reply #77 on:** February 25, 2011, 08:37:53 AM »

Great to hear Fuzz. I might look at yours closer if I can't get things sorted on the Yaffes. Cheers, Silvr

SilvrBulet · « **Reply #78 on:** February 28, 2011, 12:50:20 PM »

Quote from: FUZZNUTS on February 25, 2011, 07:18:23 AM

SilvrBulet, I have the tallest C.V. that you can buy. XXL, I also cut an 1 1/2 off the top of the wind shield. (while on the bike) The C.V. is now at the bottom of my nose. I hate looking thru a windshield. However my bars do not hit my shield at full lock. Not even close............................Fuzz

Hey Fuzz, I looked at your pix again and believe you have your handlebars mounted farther back than mine. I've attached a pix to show what I mean. When I mounted this CV, I had to move my handlebars back 1/2" to allow the handlebars to move full lock and for the fork lock to work. Given a choice, I'd take the 1/2" back. I fiddled with the mirror stalks and bought back enough to enable me to put the controls back to a comfortable position. Rather than trimming the windshield, I think the problem would be solved if I could alter the mirror stalks to where the mirrors would sit forward slightly. Has anyone tried or had success with this? I like the look of the stock mirrors and would prefer not to swap them out if I can avoid it. Again, great job on the new bars and an interesting post - it's always great to see folks fabricating cool parts! Cheers, Silvr

FUZZNUTS · « **Reply #79 on:** March 01, 2011, 08:26:58 AM »

Quote from: GH on February 22, 2011, 08:04:20 PM

Thanks for posting the pics Rich. Have you got any miles on em yet or are you snowed in like I am??

Finally a half decent day Sunday. 54 Degrees and sunny. The roads were suprisingly dry. I went out for an hour and a half with a obligitory stop at a watering hole. However the ride was very comfortable. No more leaning forward to reach the bars. It took me a whole 5 minutes to get used to a more upright position. I did give the bike a mini stress test doing a few minor twistee's, no issues. And the Punch cigar and the 2 Tröegs Mad Elf topped the ride right off.

.........................................................................Rich

FNGw/08SERK · « **Reply #80 on:** March 01, 2011, 08:22:25 PM »

Atta boy Rich ... look forward to seeing these bars in person!!!

Author Topic: Modifed SERG Handlebars (Read 16834 times)