I'm gonna be getting my Big Buffalo apes any day now, and plan on running the wiring through the bars. Is there anywhere I can find instructions WITH PICTURES on how to do this? I found the article in the tech articles section, but with no pics.

Thanks,
:-DD.

I have the wiring run internally on my Bulldog bars. They are 1.25" so it was a little easier. Shrink tubing, solder, thin coat hanger, wire, electrical tape, and a LOT of patience. It's worth it.

Baron's Tips

Doc

thebru wrote:
I have the wiring run internally on my Bulldog bars. They are 1.25" so it was a little easier. Shrink tubing, solder, thin coat hanger, wire, electrical tape, and a LOT of patience. It's worth it.

I bought the Big Buffalo 1.5" bars, so I'm guessing it should be a lot easier with that diameter. Thanks for the advice!

:-DD.

DocShadow wrote:
Baron's Tips

Doc

Perfect! Thanks so much, Doc! That's what I'm looking for!

:-DD.

Here's a trick somene showed me when I wired my wife's bars. Use a long piece of dental floss, start it in one hole, use a shop vac at the other end of the bars to pull the floss through. once it's through you have a fish line! Tie or tape to your wires and pull.

MIDNIGHTCRUISER wrote:
Here's a trick somene showed me when I wired my wife's bars. Use a long piece of dental floss, start it in one hole, use a shop vac at the other end of the bars to pull the floss through. once it's through you have a fish line! Tie or tape to your wires and pull.

Great idea buddy - thanks! I'll try that!

:-DD.

I have probably put wires inside of handlebars more than fifty times. I use a twine like carpenters use for a chalk line. You can suck it through the bars with a vacuum cleaner. After you have lengthened the wires, stager the ends each one an inch shorter than the last. lay the string along the wires and wrap with masking tape. You then pull the wires through the bars; the reason for stagering the ends is th have the bundle gradually get bigger, not have a big lump. The wire is not stiff enough and cannot be pushed through the bars. Most of what I have done has been HD's with 1" bars and 6 wires on each side. If you want some help don't be afraid to call me. I do not have any pictures and don't have a camera. If necessary I can make some drawings and FAX or mail them to you.

Clifford

Clifford wrote:
I have probably put wires inside of handlebars more than fifty times. I use a twine like carpenters use for a chalk line. You can suck it through the bars with a vacuum cleaner. After you have lengthened the wires, stager the ends each one an inch shorter than the last. lay the string along the wires and wrap with masking tape. You then pull the wires through the bars; the reason for stagering the ends is th have the bundle gradually get bigger, not have a big lump. The wire is not stiff enough and cannot be pushed through the bars. Most of what I have done has been HD's with 1" bars and 6 wires on each side. If you want some help don't be afraid to call me. I do not have any pictures and don't have a camera. If necessary I can make some drawings and FAX or mail them to you.

Clifford

Hey Clifford, you have a PM - check your mailbox..

Thanks for the advice.. sounds like a bunch of good ideas! Thanks for the offer on calling you, etc. I'll let you know how it goes once I get those bars. And thanks again for being that invaluable resource to all of us clinic members!

:-DD.

What I did was to feed some string into the handle bar ends and just blew into it until the string came to the center hole. Fished it out with a piece of wire. No need to get any more equipment than a "huff and a puff". Of course, you will need to do this in private because it looks way more than a bit strange.

Strip off about six inches of the gray plastic covering in the center of the wire bundle, stagger the cuts, splice the wires as directed in the Barons article, and be sure to mark the wires in a manner that can't be compromised by the process of feeding them through the bars. Insure that the edges of the holes are radius smooth. Once the wires are fished out of the hole think about how you are going to cover them before you splice the connector ends back on. I use stainless steel wire mesh that I got from a water hose ice machine connector for $7 at Lowe's. I pushed it over the wires and into the hole in the bars before finishing the last splices. After I was done with the splice I gently pulled the wire mesh back down the wire so that I had enough to cover it all the way from inside the bar to inside the headlight. If you mess up your markings you can use a continuity testor to ID the wires from the switchs. Good luck.