Handle Bar Extension Success - BMW Luxury Touring Community
 
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post #1 of 17 Old Dec 22nd, 2005, 6:01 pm Thread Starter
 
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Thumbs up Handle Bar Extension Success

As posted earlier I have now successfully extended my handlebars 1.5 inches using the following method.
Remove handlebar covers and you will note that the bars reduce from 1.125 OD to 0.875 OD. From this reduction point to the bend in the bars (where the grips are) there is 1.6 inches of straight 0.875 OD tubing. Cut this tubing at the center point which is .80 inch from the reduction point. (before you do this remove the heated grips as the wiring for these runs through the bars -{ please don't ask how I found this out ...LOL } Referrence all points with a marking pen so that you can re-align everything.
Purchase six inches of steel tubing with an ID of 0.875 inches and cut this into two 3 inch pieces. Slide the 3 inch tube onto the stub on the bars and then slide the other stub that is holding the controls into it. I used this opportunity to angle the handgrips up slightly as I find this more comfortable. I used JB Weld and then ran a rolled spring pin through each joint (this is not a location that I want to have come apart at any speed).
It was necessary to "tweak" the plastic bar covers but this allows for space for Ram Mounts for more farkles.
It's amazing what a difference an inch and a half makes (that ought to get a few reactions !!)
I hope that the attached photo's make my dis-jointed instructions clear.
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post #2 of 17 Old Dec 22nd, 2005, 6:08 pm Thread Starter
 
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Unhappy Photo's this time?

Lets try this again with a smaller file size.
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post #3 of 17 Old Dec 22nd, 2005, 9:07 pm
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You're the man! Good job!



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post #4 of 17 Old Dec 22nd, 2005, 9:18 pm
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Nice Job Roy!!!!!!!!!!!!!!!!1

Can you please take a pic that shows both handle bars with the covers? Maybe from the drivers seat? I might attempt this mod this winter!

Thanks,

Rob V.B.
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post #5 of 17 Old Dec 23rd, 2005, 2:26 am Thread Starter
 
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Rob - The bike will not be back together until February as all the pieces are at the painters. I will post a completed photo as soon as possible.
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post #6 of 17 Old Dec 23rd, 2005, 5:47 am
 
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You're a brave man - nice job. Does your twist grip still rotate freely and snap shut when released? The acid test will be seeing if your cruise control still works in February!
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post #7 of 17 Old Dec 23rd, 2005, 6:03 am
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Quote:
Originally Posted by beemerlt
You're a brave man - nice job. Does your twist grip still rotate freely and snap shut when released? The acid test will be seeing if your cruise control still works in February!
Nice job, You may have to re route the cables to get proper free play at the grip. The cruse control cable itself(bowden cable) is not effected. But as David said the twist grip has to be right, If not CC problems
Pete Murray
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post #8 of 17 Old Dec 23rd, 2005, 7:36 am
 
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Top work!!
a gallon of JB weld hold damn near anything in place.

I swear by the stuff
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post #9 of 17 Old Dec 23rd, 2005, 7:45 am
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Quote:
Originally Posted by Dezrae
Top work!!
a gallon of JB weld hold damn near anything in place.

I swear by the stuff
I'm gonna make a bike out of it!



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post #10 of 17 Old Dec 23rd, 2005, 1:14 pm Thread Starter
 
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Thanks David & Pete. I should have mentioned this in my first post. I have ordered new throttle cables (mine are and always have been stiff) and I will be re-routing them slightly to accomodate for the increased length.
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post #11 of 17 Old Dec 23rd, 2005, 1:39 pm
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Quote:
Originally Posted by Dezrae
Top work!!
a gallon of JB weld hold damn near anything in place.

I swear by the stuff
Maybe so, but on things like handlebars, I'd feel a lot more secure with a good old fashioned WELD.
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post #12 of 17 Old Dec 23rd, 2005, 2:10 pm
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That's what I was going to say

I wouldn't trust my life to JB weld....I'd take the bars to a welder and have the mod made permanent.....but the theory looks good...

Spence

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post #13 of 17 Old Dec 23rd, 2005, 2:20 pm Thread Starter
 
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Lightbulb

Looks like you missed the point in the original post --- in addition to the JB Weld I also used rolled spring pins.
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post #14 of 17 Old Dec 23rd, 2005, 3:59 pm
 
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Quote:
Originally Posted by jorawro
Thanks David & Pete. I should have mentioned this in my first post. I have ordered new throttle cables (mine are and always have been stiff) and I will be re-routing them slightly to accomodate for the increased length.
Roy, Before you install the new throttle cable's. Are the cables the 05 version? I installed the 05 cables huge improvement.
Pete Murray
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post #15 of 17 Old Dec 23rd, 2005, 4:10 pm
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Quote:
Originally Posted by PeteM
Roy, Before you install the new throttle cable's. Are the cables the 05 version? I installed the 05 cables huge improvement.
Pete Murray
Agreed. The metal guides in the '05 throttle cables swivel, which should allow you more reach with less binding than the older, hard-plastic guides.

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post #16 of 17 Old Dec 23rd, 2005, 8:10 pm
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Nope didn't miss it

Don't get me wrong... <g>
It's a great solution to the problem with the exception of the jb weld....the pins probably won't shear off in a collision but I just wouldn't trust it......

Any engineer here is gonna tell you that your mod is unsafe the way it is...
No manufacturer would put a set of bars together with pins and epoxy.....

Now Maybe your arms will break before the bars snap off and you impale yourself on the remains but 20 bucks at the welder and it'll be fer sure fer sure..........

I just think something as important as the handle bars should be welded that's all... Your idea is great and I certainly admire your ingenuity.

Just worried about your life bro...

Spence

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post #17 of 17 Old Dec 23rd, 2005, 8:37 pm
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Axial Tilt is the real reason for the season.
23.5 degrees is the truth
I am not in favor of Axial tilt ,I guess we have to wait until April for Axial realignment.
Pete
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