Custom handlebar clamps

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MadNick:
Afternoon,

I had a busy evening.

The first task was to separate the two halves of the clamps -

Ending up with -

Very pleased at this point that there was plenty of meat left between the clamping bolt chambers and the handlebar hole. I did realise however that the amount of thread in the 'cap' was nowhere near enough to support the clamping bolts - I reckon there was so much swarf in there from machining the tap wouldnt reach the bottom.

I tapped these out a bit more but really need a bottom tap to finish off - ive got a brand new spiral flute tap here, would that be ok to use?

Preliminary fitting -

They look good although you can see where the clamps are not quite closing properly (thats black paint in the picture) - I guess my 1" slot drill must have been quite worn. When fitted, one side of the clamps make the handlebars look a close fit whilst there is some air at the other. Having blacked out the bore and rotated the handlebars around a bit we can see the following high spots on one pair -

Do you have any suggestions for taking the high spots out and getting a closer fit whilst keeping a uniform radius parallel to the base? Have to be careful because if too much is taken out the clamps wont close enough on the handlebars.

Any suggestions are very welcome.

Nick

hopefuldave:
To get the high spots down, you could go Retro (appropriate for anything to do with a Harley...)

A bearing scraper: take a triangular riffler file (preferably old and worn!), heat to "boiled carrots" and allow to cool slowly to take the hardness off, then grind off the teeth and sharpen the 60-degree edges, harden (boiled carrots again, quench in water or oil), polish up with emery cloth and temper to light straw, then hone the flat faces on a fine stone until you get "razor sharp" edges - eeeh, takes me back... A decent file's steel will be almost glass hard after this, and should scrape the high spots down fairly well, even in stainless.

Just my ha'pennorth,

Dave H. (the other one)

The Steamer:
One thing ive noticed over the years is the handle bars are very often far from round. the bending process of the bars makes the tube oval and a right royal pain!!!

Jonny:
How do you set the centre, position and tighten up the handlebar when on the bike?
Unless you drill through the top yoke.

Theres quite a lot of force on the bars, when done give it some see if they move.
Ive had bars collapse not nice, with M8X1.25 pitch bolts going in 15mm cranked up.

You could try lapping the alum with an undersize bar for a tight fit, mind you dont roll the edges. Or spin up slow a 25.2mm bar with fine grinding paste when mounts are loosely clamped, just close up mount with one hand.

MadNick:
Morning,

I agree with your thoughts - some kind of lapping arrangement is needed.

Im toying with the idea of a kind of brake shoe assembly wrapped in emery cloth and then inserted into the assembled clamps and spun, moved up and down.

--- Quote from: Jonny on February 15, 2012, 04:37:18 PM ---How do you set the centre, position and tighten up the handlebar when on the bike?

--- End quote ---

The clamps are attached to the bike with the handlebars removed - the clamping bolts are hidden, flush with the base. It will be a pain to set up but the bike is a custom build and all about aesthetics.

Will let you know.

Nick

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