Location: Santa Maria, CA Otherwise known as heaven on earth.
Posts: 1,797
Handlebars on the cheap
Last week, I decided to make a handlebar specifically for lane splitting. The 7/8th inch tubing was already on hand from another project, so I took it to work and after hours fish mouthed the necessary pieces on the Bridgeport and Tig welded it all together. While the configuration may look a trifle unusual, this was necessary to experiment with angles and to make sure it could be narrow enough.
Three views of the nearly finished installation.
Rear view:
Front overview:
Front detail: Notice brake manifold on the end of the master cylinder.
There was no room for the stock clutch cable, so I used one from an earlier Honda, I'm not sure but think it's for a CB350, and ran it over the top of the triple clamp. As you can see from the front detail shot there was no way to make the stock brake line work at all, but since I already had SS lines with AN fittings, I machined a quick manifold for the end of the master cylinder to feed both lines and give them the proper angle to clear the instrument cluster. Despite the impression from the rear shot, when riding the tach / temp gauge is completely visible: in fact the only thing not visible is the right turn signal indicator. There is plenty of tank clearance with the stock steering stops.
The dimensions are as follows -- the width to the ends of the grips is 572 mm, so my hands are right in front of my shoulders, a configuration I found I liked in my TZ250 days. The rise is 45mm, but the bars are angled down about 20 degrees, so my hands are 15mm lower than that. In its present configuration the set back is 50mm but I'm thinking of pushing them forward another 5mm. All that's left to do is trim the ends flush with the grips.
The first ride with them was a revelation: in the twisties the control and feedback are greatly improved despite being 90mm narrower than stock, the reach to the bars is more to my liking, and on the freeway the wind holds me up just enough to barely touch the bars -- much more comfortable! Oh yeah, lane splitting is considerably easier as well. If my shoulders will fit through the gap the bike will too -- much more confidence inspiring. The only down side is the mirrors are pretty much useless unless all I want to see is my forearms , so I'm working on a pair of double mirrors with a small diameter slightly convex mirror mounted below the end of the bar reflecting to a second mirror close to center, which will give an adequate view as long as I get the optics right. Should be interesting.
Once I finalize all the dimensions I'll remake them without the adjustable clamps, and with a quick rise just outside of the mounts instead of inside as they are now.
Total cost without the SS lines was zero, it took 2 1/2 hours to make the bars, another hour to make the brake manifold, and the better part of a weekend to install and get them adjusted properly: not bad for a complete custom prototype fit up!
Infinitely adjustable, made of the finest materials available, and completely sourced from local suppliers -- gotta support the local economy! Order today and know handlebar Nirvana.
Awesome job! Looks like it would be both comfy and sporty to ride. The prototype looks cool, I'm sure the finished product will be very impressive looking!
Your work never ceases to amaze. I kind of like the look of the rise inside of the mounts.
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I feel sorry for people who don't drink. When they wake up in the morning, that's as good as they're going to feel all day. -Frank Sinatra
Location: Santa Maria, CA Otherwise known as heaven on earth.
Posts: 1,797
Finally!
It's been a month, but the leg now has sufficient ROM to get to the footpeg, so I finally had an opportunity to give the bars a good test.
In a word: excellent! After some minor tweaking and adjusting, they feel just right for my riding style despite being tenative about moving around on the bike while setting up for corners. Feel is much better than stock, with clearer messages from the front tire, and even downhill braking doesn't have me putting too much weight on the bars. In point of fact it feels so familiar from production racing that the adjustment period was about three corners. The mirrors are gone -- replaced by a single slightly convex bullet mirror. I have one for the other side, but it will wait until I pull a mold for a turn signal lens to integrate into the mirror body. One of these days I'm going to buy something that will just bolt on ... naaaaahhhhh!
One thing's sure -- with the increased load on the front end it desperately needs a Pilot Road 2CT as soon as possible, which is not a bad thing as the 2CT on the rear has completely trashed the front Road in less than 1/3 the mileage I normally get from them. Another reason to match tires, but it was fun to feel the front tire tucking in during corner exits, and completely controllable as well -- thank you Michelin.
Just one more shot to show the mirror, which gives a pretty good view.
Well, it's off for another ride -- feels good to be back in the saddle!
Infinitely adjustable, made of the finest materials available, and completely sourced from local suppliers -- gotta support the local economy! Order today and know handlebar Nirvana.
I had a set of clubman bars that I tried on my 919, but I couldn't make it work - brake line wouldn't fit, and the bars hit the tank. Your setup gives the same riding position as the clubmans and solves the two problems I couldn't work out. Kudos.
Location: Santa Maria, CA Otherwise known as heaven on earth.
Posts: 1,797
Quote:
Originally Posted by swilly
When are you going to fab them for sale?
-tom
As soon as I get back to my machine shop at work I'm giong to remake them in a more conventional fashion -- the adjustability was simply to get the angles right and to insure they could be narrow enough. It's actually very much in the way of getting the key into the ignition.
Here's a CAD drawing of the production bars -- the rise will be outside the clamps (barely).
Be advised as well the stock brake line won't work, and it will take some creativity to rig SS lines as well -- look at the third picture in the thread starter post to see what I had to go through to get it hooked up. G&J has right angle banjo fittings that could be made to work with a little creativity, you will need a different clutch cable as the stock one's bend at the perch just cannot be fit up, and in general it will not be a "buy it and bolt it on" modification. Mirrors will be another issue especially if you aren't using bar end type, but that's your problem. Vibration may also be an issue: there is practically no space between your hands and the bar clamps, so no matter what you do some vibes will get through. I don't find it objectionable on the freeway because my hands barely touch the bars at speed.
Let me know if you're still interested after all this, and I'll work up the necessary jigs to make more than one and give a time frame and probable cost.
Infinitely adjustable, made of the finest materials available, and completely sourced from local suppliers -- gotta support the local economy! Order today and know handlebar Nirvana.
Glad to hear you're back in the saddle! Also good to hear that the bar design feels so good out on the road. I had wanted something that had the look of a low MX bar, but with the downward slope of clip-ons (but above the top triple instead of below). It looks like yours is a pretty good compromise between both styles.
Great work!! Can't wait to see photos of the finished product on your bike!
Location: Santa Maria, CA Otherwise known as heaven on earth.
Posts: 1,797
Bump, and an update
Hello everyone!
It's been a hell of a year! More on that elsewhere.
Here's the latest on actually producing my adjustable lanesplitter bars.
During this "Hell of a Year", I've been refining the design until it became producable (very important) and satisfied my vision (much more important, and a heck of a lot harder to do!), so here it is.
A comparison between Renthal Ultra Lows and my design. :
To the left is an example of the height attainable similar to the originating post. The point is the risers can be placed either inside the clamps for low and narrow, or outside if you are looking for more everyday riding. It must be stated that my preference is as low and narrow as possible (DUH!), but you may not be as hard core as me.
Whoopee, right? What use is a picture, or even a digital file? Hold on to your skivvies:
In conjunction with a local CNC machine shop, and with their considerable help in the looks / cost / manufacturability equation, these are shots of the clamps after the first operation. They are machined from certified 6061 T6 stock (2024 is too damned expensive!), and I'm using stainless 8MM grade 8 hardware. Actually, they are WAY overbuilt, but better a few ounces too much than a gram too little.
The tubing I'm using is 7/8ths" .049" wall 316 stainless, primarily due to my extensive experience with it, it's corrosion resistance, a cost only about 8% higher than 4130 steel, and superior properties for this application.
The design is specifically for lots of adjustability, in fact the stub the actual handle part of the handlebars attaches to is angled to the centerline of the clamp enabling turning them around for flatter bars. Unless you are making major adjustments the only tool needed is a 6mm allen wrench. Also, I'm worknig on spacer pieces to obviate the need for drilling the bars for every minor change until you are satisfied with the position. These will be available separately for anyone installing bars of any description (as soon as I line up a supplier).
Here's the deal -- I'll probably be ready to ship a couple sets in 2 to 3 weeks, and I'm giving them away to the right people. I know -- define "right". Okay, I will. They will go to someone who has a reputation for mechanical ability, riding talent, a demonstrable penchant for finishing what they start, and a willingness to give me as much feedback as possible. Only in this way can I put the finishing touches on things and hit the market.
All who wish to be considered please post up breifly and PM me with your qualifications and, well, why you should get them. The final decision rests with me exclusively, and whining if you are not chosen won't stand a snowball's chance in hell of changing my mind. I will not reveal the specific criteria I use past what I've already said as most of it will be visceral.
Robert Tharalson, CEO; head of R&D; bottle washer; and floor sweeper: Thar Engineering
Infinitely adjustable, made of the finest materials available, and completely sourced from local suppliers -- gotta support the local economy! Order today and know handlebar Nirvana.
I single-handedly installed a TAG Metals mini low bar on my bike. Does that qualify me? Oh, and I won a drawing for a half-price track day and free leathers and boots. I plan to use it one day, too. Guess I'm a shoo-in now. Right?
Seriously, cool set-up. If you can get your price lower than the Suburban Machinery type 2 bars (around $150), I think you'll steal a lot of their market. The guys at SVRider.com would go wild over those things.
Have to wonder whether the bar-end mirrors defeats your stated lane-splitting purpose, though. Won't the bars + mirrors put you right back in the same ballpark, length-wise, as a "normal" set-up?
Looks like you got something here, Rob. I've been considering (and almost purchased) a set of Converti-Bars, but I didn't want to spend $350 for a set. They are clip-ons type bars, so I didn't like the idea that it would leave me with a set of "empty" bar clamps on my triple tree. This is perfect for bikes with handlebars, like how most nakeds are set up.
As you know, I am playing around with different bar setups on my 919, with the most drastic being the Clubmans I'm setting up recently. I would definitely be interested in a set of these bars, particularly the outside risers design.
I do alot of different types of riding. I'm a Level 2 Trackday rider, and the 919 is my trackbike. I also, like many of us, like to take spirited rides through the backroads, as well as do alot of highway miles being in Houston. I also do mission rides for the Patriot Guard Riders, where we do alot of slow, deliberate riding as we escort Funerals for fallen soldiers. My bike needs to serve many purposes, and handlebars that offers a decent range of adjustability would be ideal for the many different types of riding I do.
Location: Santa Maria, CA Otherwise known as heaven on earth.
Posts: 1,797
Quote:
Originally Posted by BigMike919
Holy Crap that's cool!
Quote:
Originally Posted by Border
That's extremely cool Rob.. I like the concept and especially the adjustability. What kind of CAD do you play around with for design?
Yeah, I think it's cool too -- I'm walking around the house with the clamp in my hand like I'm a one year old with a favorite toy.
I use Punch! Via Cad 2D / 3D. Got it at Fry's for about $50. On the cost versus usefulness scale it's right off the top. There is a professional version for around $500. Play with it? PLAY WITH IT? You hit the nail on the head. It is play.
Quote:
Originally Posted by sugs
Well, I guess this rules me out...
Looks really good Rob. The way your drawing looks, is there going to be a choice of center section?
The only thing that would rule you out is you telling me you're not interested ... or maybe still having a pair of calipers in a box for a year.
The center section is quite changable, at least at my end, and having the risers outside the clamps would be preferable if you don't necessarily want the bars as narrow as possible.
Quote:
Originally Posted by jay313
I single-handedly installed a TAG Metals mini low bar on my bike. Does that qualify me? Oh, and I won a drawing for a half-price track day and free leathers and boots. I plan to use it one day, too. Guess I'm a shoo-in now. Right?
We'll see. Nothing I've read so far excludes you.
Quote:
Seriously, cool set-up. If you can get your price lower than the Suburban Machinery type 2 bars (around $150), I think you'll steal a lot of their market. The guys at SVRider.com would go wild over those things.
I've heard a lot of comparisons between my bars anb Suburban Machinery bars, but, of course, mine are adjustable.
Quote:
Have to wonder whether the bar-end mirrors defeats your stated lane-splitting purpose, though. Won't the bars + mirrors put you right back in the same ballpark, length-wise, as a "normal" set-up?
What is behind you, especially when splitting lanes, is not important. Literally. The one tiny, overtinted, and distorted bullet mirror is fine for me, and only adds about 15mm to the width. If you are looking for wider or taller bars my design can be set up for it. Mirrors are less of a problem in this case.
Quote:
Originally Posted by Basspiece919
Looks great, improved Suburban machinery bars. Which is HARD to do, because my SM bars are pretty much completely perfect...
Pretty much perfect is good. Perfect is better. Mine can be.
While it's a bit early in the game, I anticipate a retail cost in the $125 to $145 range. I'm in the process of designing for castings instead of CNC milled, which can be significantly less expensive in sufficient quantities.
Infinitely adjustable, made of the finest materials available, and completely sourced from local suppliers -- gotta support the local economy! Order today and know handlebar Nirvana.
Those are trick! If your HB make the gap you are home free!
Did you calculate the strength of the two unique joints, compared to renthals? I've hit a few deep potholes 2up and was impressed the renthals didn't break.
Location: Santa Maria, CA Otherwise known as heaven on earth.
Posts: 1,797
Quote:
Originally Posted by dream
Rob,
Those are trick! If your HB make the gap you are home free!
Did you calculate the strength of the two unique joints, compared to renthals? I've hit a few deep potholes 2up and was impressed the renthals didn't break.
The bars are designed with "stepped failure" in mind -- The strongest part is the clamps, followed by the center section, then the handle tubes bonded and screwed to the clamps. In the event of a fall, the handles will bend, and I guarantee not break, before any other component is stressed anywhere near it's limit. In this case the handle tube(s) can be easily repaced without even removing the bars from the bike. Total cost of the repair should be about $10. Not many others can claim that. Even if the clamp fails in a major get off the cost of repair would be a small percentage of the original purchase price of the bars.
Notice I did not say fail while in use -- I can't conceive of a riding situation that would break the bars without depositing the rider on the ground first.
Infinitely adjustable, made of the finest materials available, and completely sourced from local suppliers -- gotta support the local economy! Order today and know handlebar Nirvana.
I've heard a lot of comparisons between my bars anb Suburban Machinery bars, but, of course, mine are adjustable
Which is why I think that if you can come in slightly under (or reasonably close to) the price of SM bars, you'll steal some of their market. Nice product. Just gotta figure out how you want to market it.
'02 Honda 919 - She's the only one for me!
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