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/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Drilling Sissy Bar... what kind of bit? /cgi-bin/YaBB.pl?num=1306178410 Message started by blackhalo on 05/23/11 at 12:20:10 |
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Title: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/23/11 at 12:20:10 I have an aftermarket hardtail sissy bar that I'm attaching to the shock mounts... the holes in the sissy bar aren't big enough to mate with the thick shock bolts... so I need to drill them bigger. The sissy mounts are 1/4" thick chromed steel (I'm not worried about the chrome)... it's a straight shot through the existing holes, but I only have a hand drill. I think the shock bolts are are 1/2" diameter (so I need to double the hole size in the sissy)... since 1/2" (carbide?) drill bits are kind of expensive... I need some advice here. Do I need a drill press to do this? If not, what kind of drill bit should I be looking for? And what kind of time investment (vs drill press)? I'm just trying to decide whether I should spend the $75/hour for a machine shop to do it. Appreciate any help people can offer... this issue has been holding up my project for a while now. Here's a pic of the setup: http://img19.imageshack.us/img19/2771/img0878w.th.jpg (http://imageshack.us/photo/my-images/19/img0878w.jpg/) |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by Serowbot on 05/23/11 at 13:29:13 Na,... I'll bet any ol' steel drillbit will go through there... as long as it's nice and sharp... You might want to go 3/8",... then 1/2".... to keep the hole even and smooth... Put a block of wood under it, so when you punch through, you don't drill into your table or floor... You definitely don't need a press for that... ... if you have a bench vise, clamp it in there,.. if not, just stand on it... easy as toast!... ;)... |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by thumperclone on 05/23/11 at 13:30:10 got a good electrican friend? borrow his 1/2" K.O. cutter or a hole saw with 2x4 under as support |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/23/11 at 15:36:31 Well, I got impatient and just grabbed a cheapo set of titanium from HomeDepot... got back and gave it a shot a minute ago, easy as pie!! Unfortunately, the shock bolts are just slightly BIGGER than 1/2"... so I got a hole, but it's still not big enough! HD didn't have a lot of bits larger than 1/2"... the rest were heavy industrial bits (like a foot and a half long). So now I have another problem... those bigger bits don't FIT into a normal drill... even if I bought one, I can't use it. I'm so close too... so I took a Dremel with a little sanding pole 'thing' and tried grinding it out... I think it worked a bit, but the little grinder attachment just wasn't up to the task, it ground down and broke... real fast! Honestly, it only took maybe 3 minutes to drill it... so I have to wonder if this sissy bar (mount) was made out of aluminum... it's still chrome colored inside (it's a Paughco sissy bar... they know what they're doing --- and I don't!)... LOL! Does Dremel have any heavier duty attachments that might work in this situation? I don't think drill bits are an option anymore... and it's sooooo close! |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by Serowbot on 05/23/11 at 16:09:47 Cheating 101... Put the 1/2" bit back in there and drill while tilting the drill angle back and forth. You can fudge the whole bigger... ... or,.. buy a round file... Use a magnet to check if it's steel... ;)... |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/23/11 at 16:24:01 Oh, I tried cheating... didn't seem to grab anything, although I was really just pushing sideways (rather than tilting)... maybe, maybe. I may just do the file... it's really that close. Of course, all I have on hand are tiny files that would take forever. I'm almost ready to just grab a blowtorch and a spoon... just scoop out the molten metal! hehe! Magnet: Ha, great idea... I just checked, and it sticks!! (weird, extra thick chrome????) |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by Serowbot on 05/23/11 at 16:29:16 I'm guessing it's it's just a soft steel. ...better that it bends under pressure, than snaps off... If you still think it might be aluminum,... check the drill shavings with the magnet... ;)... |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by Max_Morley on 05/23/11 at 18:08:26 How about the largest step drill? They are always nice to have around. |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/23/11 at 18:33:39 Some of the chrome flaked off the side, it's steel underneath... I guess the chrome that was already in the hole got blended into the sidewall. I tried a Step Drill Bit in the first place... I didn't get anywhere though, it wouldn't grab anything (just dust)... that may be why the chrome got mashed into the sides tho. So I went to harbor freight a picked up a cheap round file... $2.29! then I went on the back porch and started filing (under the green floodlight)... it was too hard to see... and I started feeling like a criminal, filing metal in the darkness. ;D I'll give it a go tomorrow... fingers crossed it rounds-out as easily as it drilled. |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by Gyrobob on 05/23/11 at 19:00:58 Get a 15/32" drill and glue a 1" wide by 1.47" long strip of some good wet or dry 80 grit sandpaper on it past the point where the flutes stop. This will make a .5" diameter abrasive file. Use some fluid (water will be fine), and with your home-made file turning slowly in your drill (drill press if available), slowly hog out the hole a few thousands of an inch at a time. Do this until it just fits. If you turn it too fast or don't use any fluid, you'll just dull the 80 grit paper. I've used this trick using material from a belt sander belt that had broken into pieces. It works nicely if you are patient. If you are in a hurry, just hog it out with a file and accept a less than round hole that might not be exactly perpendicular. |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by justin_o_guy2 on 05/23/11 at 19:03:57 Grab the drill, run the bit thru only 1 side of the sissy bar, spin it up & swing the drill in a wide circle, thatll chamfer the inside & outside of that piece, leaving only a sharp edge at the drill bit, the file will finish that off easy, then do the other end of the hole, then, flip the thing & do it 2 more times.. |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by WD on 05/23/11 at 20:16:10 Any real hardware store will have the 9/16" bit you need to fit a 3/8" drill chuck. $15-20. Run it SLOW and use some cutting oil on it. They'll have that there too. |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/23/11 at 21:15:34 Awesome ideas guys, thanks for the help... at this point I'm just trying to avoid buying another $20+ drill bit, adapter, etc. But I may consider adapting the hand file to my drill (thanks Gyrobob)... that should be faster than grinding by hand... even on 'slow'. Justin_o_guy2: I did 'cheat' for a while this afternoon, even got the bolt to slip into one half of the hole... but it took 40 minutes of slow fighting (and there's still three more sides to go). That's when I gave up and bought the prison file... between the two I should be able to find the path to the next step (fender mount)! More pics (and questions) to come as things progress... I'm taking this project all the way (homemade, no kits)... new tank, bars, the works! We'll see what happens! |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by WD on 05/24/11 at 06:04:29 If you decide to go the next step and strut it (poor man's hardtail), go to O'Reilly's and get a set of lift shackles. The generic $25 ones in the towing/add a leaf section. Enlarge the holes to 9/16". I'm using an old dirt tracker tank on mine. Drilled the frame where the downtube reflectors were attached to the neck gusseting. HD Softail front mount kit. Rear tab held on by seat front mounting bracket. This winter I'll smooth the frame and repaint it. Suzuki's have some of the ugliest welds I've ever seen on a metric. The spatter wasn't even ground off mine before it was painted. |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/24/11 at 10:58:35 Hehe, actually I found a pair of black anodized struts on eBay for $15... but it turns out the advertised specs were wrong. They were only like 7" total, eye-to-eye was even less... had to send them back, and they couldn't replace. :( I still want to dabble with hardtail, but I'm gonna wait a bit, come back to it later. I'm testing the fender mounts with rubber stoppers, instead of washers (or spacers)... I'm hoping the rubber stoppers provide enough flex for the shock/sissy bar movement. Obviously, I don't want the fender fighting the swingarm... so I'll tighten up the shocks if I have to... then move to hardtail, if I must. I know, it's unconventional... but it should work. XfingersX I've already got the stoppers drilled (couldn't find rubber washers big enough), and it's all looking pretty good... I just gotta get this sissy bar mounted, so I can decide where to cut the fender! Drilling these holes has been a big hold-up... that's almost done! |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/24/11 at 16:22:53 New Problem: Bending metal... :( Got the sissy bar on (grinding the holes only took 10 minutes)... but the stupid fender mount isn't offset, even though it's a belt drive sissy (wider). http://img836.imageshack.us/img836/3184/img0933m.th.jpg (http://img836.imageshack.us/i/img0933m.jpg/) http://img821.imageshack.us/img821/5200/img0944f.th.jpg (http://img821.imageshack.us/i/img0944f.jpg/) I figured I could fudge it somehow... but at this point I can't even mount the fender to the frame properly, so it really only comes down to TWO real options: 1) Bend the fender mount to the right, maybe one inch... providing me enough room to mount straight. 2) Buy a 7" fender, which I really didn't want... after I put on a peanut tank, z-bars, and a 9" solo seat, the 6" fender keeps things sleek. So my question is... can I bend the fender mount? We're only talking about an inch here (and the chrome is not an issue)... so I'm considering it... but I don't have a clue how to go about it. Blowtorch and a rubber mallet? Vice clamps? |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by Serowbot on 05/24/11 at 16:26:12 I would bend the sissy bar... keep everything else in line. Plus,... it'll be the easiest to bend... |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by Johansson on 05/24/11 at 16:52:58 Instead of bending the fender mount, cut the mount off. Two cuts, leave the tab on the hump a little longer on one side. Make a pattern from a coat hanger. Mark the cuts first on the coat hanger, turn the pattern around until you figure out where to make the cuts. Turn the mount around. If you figured right, the fender mount will be right where it needs to be. Since the chrome is'nt an issue, run it to a local small time weld shop. The may not charge you, I would'nt anyway, cause it will only take a second to re weld. Offer them 10 bucks, or a twelve pack at least. |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/24/11 at 18:15:29 When I say "fender mount", I was referring to the the sissy bar... but it's pretty heavy duty, there's almost NO flex... the whole thing is rock solid. I would really prefer to 'bend', than to 'cut'... but if I screw up the 'bend', then at least 'cut' will bail me out! ;D I'm just not sure how to bend... odd angles, tight spaces, very rigid... I don't think a hammer will be able to get in there properly... I may try some kind of large ratcheting clamp, maybe. I just wonder if I should use fire? :-/ |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by Serowbot on 05/24/11 at 19:02:24 39373A3830333A37345B0 wrote:
Not on chrome... no fire on chrome... :o... Make a template of the shape you need with a piece of coat hanger, then pull the sissy and bend it in a vise (or use a doorjamb or something)... then re-install... |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by babyhog on 05/25/11 at 05:27:26 So the hump on the sissy bar that connects the sides is what the fender is supposed to sit on? Does it fit up in your fender correctly, but just off center? And is it welded on the sides where it connects to the main sissy bar? My thinking is if it rides up under the fender, maybe you can totally remove that cross-piece and replace it with something else that is shaped correctly. But maybe I'm looking at it wrong.... I do this to the guys at work, and to my husband, just to make them detail it for me.... simple terms... then a solution usually comes out of the explanation... 8-) |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/25/11 at 12:47:56 Yeah, the hump is where the fender sits (almost snug)... and the hump really just needs to slide over to the right about 1", easier said than done! One thing I should mention, I'm big on Kustom Kulture... this is gonna be a (clean) rat bike... distressed and "hand-made" style is the plan (within the limits of good looks)... so burnt chrome isn't really a big deal (actually, it may even be adopted as a paint job). I'll see how far I can get without fire tho... since I don't actually have a torch on-hand. I do have Gasoline and matches tho... :D |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by babyhog on 05/25/11 at 12:50:53 Oh, I see! So then just slide the hump on over there! ;D Keep us posted... |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/25/11 at 14:38:02 Yeah, this is sooo not happening... between the weld, and the 1/4" steel, the crossbar is as rigid as can be. Even in a vice it's not gonna move far (very awkward)... so I have to cut the weld, then bend the bar, and re-weld it. Considering a new fender is only $30... it's not exactly worth the effort to disassemble and rebuild the sissy bar. I would just as soon build the EXACT sissy bar I want, from scratch... kinda bummed, I did consider this option for a moment... then realized there's so much more work to do yet! Maybe later. :( |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by justin_o_guy2 on 05/25/11 at 19:02:59 Id bet about a dollar that if th sissy bar was in a ditch you could still ride the bike,, |
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Title: Re: Drilling Sissy Bar... what kind of bit? Post by blackhalo on 05/25/11 at 21:29:05 Yeah, but then where's the b*tch gonna sit? :-* That's the whole point here... well, that and a place to strap a backpack. Can't stand baggers, not my cuppa tea... and the old lady ain't down with long rides and nothing to lean on. We lives in Florida, everything is a long ride out here. |
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