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Drilling handlebar ends
#587832 07/02/2017 10:10 AM
Joined: May 2010
Posts: 214
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Has anyone ever drilled out the stopper in the ends of the stock handle bars?
I really want some bar end mirrors. The ones I want are nothing special Napoleon bar ends with a rubber compression stopper to keep them in place. The need to fit into the bars about an inch, but the stopper with the screw hole prevents that on the stock bars, which I like and prefer to not change.

I may buy a used pair of stock bars to test, but seems like someone would have drilled out the ends.


2009 America
Re: Drilling handlebar ends
MarcellusWallace #587833 07/02/2017 10:23 AM
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Fe Butt
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Been done pita to do.I would personally just buy a set of similar aftermarket bars to use. Aftermarket bars are not expensive.


I learned all I need to know about life by killing smart people and eating their brains.
Eat right ,Exercise ,Stay fit, Die Anyway!
Re: Drilling handlebar ends
The_Dog33 #587834 07/02/2017 11:28 AM
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Use a Bi-Metal holesaw, such as of Lenox or Starrett origin. I don't remember the size I used, but it worked great and all I ended up with inside the bar ends was a thin metal ring. Then bumped the ring remnant, it turned 90 degrees then pulled it out with some pliers. Use high sulfur cutting oil with the holesaw and you will get better mileage with it. A holesaw arbor, a pilot drill bit and the holesaw will cost you more than just taking Ian s advice and buy some similar after market bars of the same configuration. I already own all the tooling, so that's how I did it. If you do decide to cut the plug out, remember a 3/4" holesaw cuts a strong 13/16ths hole+ in metal, so your holesaw size required should be 3/32nds to 5/32nds" smaller that the I.D. of your bars, at a minimum.

Re: Drilling handlebar ends
Ryk #587835 07/02/2017 12:28 PM
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I wish me and this guy were next door neighbors


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Re: Drilling handlebar ends
Wade #587836 07/03/2017 5:14 AM
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I definitely wish Ryk was my neighbor!

Re: Drilling handlebar ends
tikiman #587837 07/03/2017 11:35 AM
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