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General Category >> Rubber Side Down! >> Custom combo bar end mirrors/bar end turn signals
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Message started by diamond jim on 02/11/09 at 05:13:55

Title: Custom combo bar end mirrors/bar end turn signals
Post by diamond jim on 02/11/09 at 05:13:55

I'm starting a new project of combining some custom low profile amber LED pods to the bar end mirrors with internal wiring through the mirror and bar. I might make these from scratch. I ordered some stuff from ebay last night to get started. I'll post as I develop these.

Title: Re: Custom combo bar end mirrors/bar end turn sign
Post by SimonTuffGuy on 02/11/09 at 05:30:57

Would this do away with the front turn signals then? I'm interested in hearing more.

I saw that Savage_Greg has a picture of one of his bikes that have a turn signal in the mirror. It would clean up the front end doing away with the stock signals, as long as the new ones could be seen just as easily.

Good luck!

Title: Re: Custom combo bar end mirrors/bar end turn sign
Post by diamond jim on 02/11/09 at 08:39:31

I took the mirrors out to put some locktite on the screw thread just in case and noticed the recessed areas that I can use to run some wiring.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021344.jpg

Title: Re: Custom combo bar end mirrors/bar end turn sign
Post by verslagen1 on 02/11/09 at 09:13:27

Is this the pocket for the mirror?

Title: Re: Custom combo bar end mirrors/bar end turn sign
Post by serowbot on 02/11/09 at 09:48:37

Looks like micro-surgery... I'm all thumbs with a soldering gun. :-?
Look forward to seeing what you come up with.

Just ordered my bar-end mirrors... ;D

Title: Re: Custom combo bar end mirrors/bar end turn sign
Post by diamond jim on 02/11/09 at 13:37:23

382B3C3D222F292B207F4E0 wrote:

Is this the pocket for the mirror?

Yep. There's about a 3/16" clearance between the flat parts of the inside of the shell and the back of the mirror. Enough to play around with.

Title: Re: Custom combo bar end mirrors/bar end turn sign
Post by diamond jim on 02/13/09 at 05:33:04

So here's what I got done last night. I removed the steel bar end weights that were in the stock drag bar. I made a channel along each one for the wire to run through. I had previously drilled and tapped the ends to accept 5/16" bolts to hold the mirrors on. That works MUCH better than using the expanding aluminum sleeves that come with internally mounted bar end mirrors.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021361.jpg

I drilled and tapped a 1/4" hole into the weights. I did this while the weights were positioned inside the handlebar so that both the handlebar and weights have lined up, matching screw threads.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021365.jpg

I ran a 1/4" headless set screw through the bars and into the weights. I screwed them in til they were flush so as not to interfere with the grip/throttle sleeve. You can see the channel for the wires.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021373.jpg

I thought about welding the weights in the bar, similar to the stock drag bar method, but decided to go with the headless screws so I could remove the weights if needed.

Next, I took a washer and made an opening in it for the wire. I used JB Weld to attach it to the bar end weights. The washer acts as a spacer for the wire.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021379.jpg

Here I put pressure on the new wire spacer while the JB Weld cures. You can see the space for the wire.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021377.jpg

Here you can see where the wire exits the bottom of the bar. I took this pic when I first started running the wires. I'll run the wires through the existing wiring covers for a nice, clean look.
http://i255.photobucket.com/albums/hh128/russ_diamond_jim/S4021376.jpg

The wire has protective heat shrink tubing throughout the section that runs through the bars. I also rounded all metal edges that the wire comes in contact with. I thought about doing the hollow threaded rod in place of the bolt but the solid bolt is stronger and gives me more flexibility for attaching things to the bar ends.

Title: Re: Custom combo bar end mirrors/bar end turn sign
Post by serowbot on 02/13/09 at 09:23:58

really enjoying your pics, ... I don't think I could follow what you're doing without it..
I also don't think I'll attempt this myself... I don't have your attention to detail... nice work..
thanks