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[Highjagger]

Which version did you order ?
Any difficulties when mounting them ?
Do you have pics of the mounting process ?

[Highjagger]

Is this the heatdemon number i would have to order :210045CET ?
Do the SERG have a 1" or 1 1/4 " bar ?

[hdbrad03]

I have Heat Demons installed. The bar area where the grips are is 1". The problem is the inside diameter is to small to install the heater and TBW. The bar must be drilled or honed to 7/8" all the way to the wiring hole. I drilled mine (was'nt easy). Yes the part number you ref I feel is correct.


 
     Brad

[Highjagger]

The number gives a choice of two variations of heat demons , 1" or 1 1/4 " , so i do need the 1" one .
You mean the bar is 1" .
The bar must be drilled out inside till the wiring hole to 7/8 of this 1" .
How much is the outdrilling?
Could one do it with the hand and sandpaper or is this impossible ?
 Is it just the chrome inside which has to be drilled away or also steel-material?

[Twolanerider]

The number gives a choice of two variations of heat demons , 1" or 1 1/4 " , so i do need the 1" one .
You mean the bar is 1" .
The bar must be drilled out inside till the wiring hole to 7/8 of this 1" .
How much is the outdrilling?
Could one do it with the hand and sandpaper or is this impossible ?
 Is it just the chrome inside which has to be drilled away or also steel-material?

That 1 to 1.25" variation is the outside diameter of the bar.  That difference is for the clamp (that contains their switch) that replaces the existing handlebar clamp.  The 1" or 1.25" measure is separate and irrelevant to the inside diameter of the bars where the elements are inserted.

The size of the inside diameter at the end of the bar would be .875" necessary for the heating elements.  If the ID is too small the elements would not lie in even contact with the inside of the handlebar. 

[Highjagger]

Aaaaah , i see ,
I need the 1" ones , right ?

The outdrilling is a very high difficult work i guess , hmmmmm , how to solve this problem
 Do i have to deinstall the hole bar ? ( for drilling out )

[Twolanerider]

Aaaaah , i see ,
I need the 1" ones , right ?

The outdrilling is a very high difficult work i guess , hmmmmm , how to solve this problem
 Do i have to deinstall the hole bar ? ( for drilling out )

Yes, if not mistaken I believe the SERGs have 1" outside diameter handlebars.  I do not know what their inside diameter might be so can not say how much material might need to be removed to allow the heating elements to expand correctly and lay flat against the bars.

If any other internal wiring that previously existed could be held completely out of the way I'd be tempted to try it on the bike though.  Perhaps with a friend to maintain a good hold on the end of the bar as the drilling or honing process began.  Might also be a good idea to push compressed air from other end while drilling to make sure any shavings do not go further down inside the bar.

If existing wiring, shavings or any other hazard could not be absolutely controlled then just take the bars off the bike and disassemble completely.  Either jig the bars up well in a bench vise (with proper padding to protect the chrome) and work with a hone or drills as necessary or take them to a machinist and have it done.

[hdbrad03]

I drilled mine on the Bike but it is not for faint of heart. I removed the TBW Sensor by de-pinning the connectors. I left the Switch housing wires installed then I plug the bar with a small rag and place a circle of metal to protect wiring from the hot metal shavings. Then I drilled 7/8" all the way to the wire opening. Good Luck

 
      Brad

[Twolanerider]

I drilled mine on the Bike but it is not for faint of heart. I removed the TBW Sensor by de-pinning the connectors. I left the Switch housing wires installed then I plug the bar with a small rag and place a circle of metal to protect wiring from the hot metal shavings. Then I drilled 7/8" all the way to the wire opening. Good Luck

 
      Brad

Brad, what was the original ID?  How much material is removed?

[Highjagger]

Do our TBW units look the same as above ?
And our " end of our bars " , too look the same ?

[Highjagger]

pics taken from here : http://www.cvoharley.com/smf/index.php?topic=29764.0;all

[hdbrad03]

Not sure Don but I would guess a heavy 1/16" was removed.



 

    Brad

[Twolanerider]

Not sure Don but I would guess a heavy 1/16" was removed.



 

    Brad

Thanks Brad.  Based on nothing more than presumption that's more meat than I expected being removed.  Not a lot of material necessarily.  But still a chore to drill out on the end of an unstable rubber mounted tube.

[hdbrad03]

Still better than applying the HD Heated Grips then Applying and Applying and Applying!!


 
     Brad

[Twolanerider]

Still better than applying the HD Heated Grips then Applying and Applying and Applying!!


 
     Brad

That's affirmed.  Have one set of heat demons in what has to be 2.5-3 years now and the other set for just over a year.  They're both like the Energizer bunny.  Just keep going and going and going and going.