Need some fabrication help - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 35 (permalink) Old 10-15-2012, 05:12 AM Thread Starter
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Need some fabrication help

So a little while back I got some Daytona-bend bars. I love the look and positioning, but the problem is that the fittings for the cables bump/rub against the tank at full lock. It looks like if I could mount them 1" forward and 1" up from where the bars currently mount that everything would be fine and still look/feel good. Problem is, offset risers like that are going to be about $90. That's WAY more than I wanted to spend.

So then I was thinking of fabricating something myself, but I'm not sure how or what to do. One thing I came up with was a piece of flat aluminum that would run lengthwise along the center of the bars, bolt into the two top holes of the handlebar clamp, and then I'd use U-bolts to clamp the bars down. That's the best I've come up with so far.

Anyone have any ideas?

'95 Vulcan 750 - Purchased 8/2003 w/ 21,124 miles - passed 50K 9/3/15
* VN900 seat * Daytona handlebar * Converted ACCTs to MCCTs * Relocated R/R * Drilled clutch basket * Coastered * Repainted *
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post #2 of 35 (permalink) Old 10-15-2012, 06:58 PM
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Why not use 7/8" risers that were made to do just what you are trying to do.

7/8" Riser


Last edited by slimvulcanrider; 10-15-2012 at 07:05 PM.
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post #3 of 35 (permalink) Old 10-15-2012, 07:05 PM Thread Starter
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The ones I found on ebay were a little too pricey, or I wasn't sure if they would work.

'95 Vulcan 750 - Purchased 8/2003 w/ 21,124 miles - passed 50K 9/3/15
* VN900 seat * Daytona handlebar * Converted ACCTs to MCCTs * Relocated R/R * Drilled clutch basket * Coastered * Repainted *
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post #4 of 35 (permalink) Old 10-15-2012, 08:07 PM Thread Starter
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I see your edit to add pictures. I've already got the top pair on my watch list. We'll see what the price is like in a few more hours.

But I think I may have figured it out. I totally forgot that I have an extra triple tree from that crashed bike I bought. I could cut off the bar mounts and install them on top of the ones on my bike. Looks like it might work perfectly. Heading out to the garage to cut them off. I'll update with more in a bit.

'95 Vulcan 750 - Purchased 8/2003 w/ 21,124 miles - passed 50K 9/3/15
* VN900 seat * Daytona handlebar * Converted ACCTs to MCCTs * Relocated R/R * Drilled clutch basket * Coastered * Repainted *
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post #5 of 35 (permalink) Old 10-15-2012, 08:42 PM
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cool, lets see what you came up with... i am very excited to see how this turns out...
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post #6 of 35 (permalink) Old 10-15-2012, 09:34 PM Thread Starter
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Got them cut off with little trouble. Now I just need to level the bottoms out. After that, there's a really good chance I'll be able to bolt them directly on. Just need to find a neighbor with a bench grinder or belt sander.

'95 Vulcan 750 - Purchased 8/2003 w/ 21,124 miles - passed 50K 9/3/15
* VN900 seat * Daytona handlebar * Converted ACCTs to MCCTs * Relocated R/R * Drilled clutch basket * Coastered * Repainted *
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post #7 of 35 (permalink) Old 10-18-2012, 09:35 PM Thread Starter
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Got it sorted out:



Really like the overall look:


'95 Vulcan 750 - Purchased 8/2003 w/ 21,124 miles - passed 50K 9/3/15
* VN900 seat * Daytona handlebar * Converted ACCTs to MCCTs * Relocated R/R * Drilled clutch basket * Coastered * Repainted *
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post #8 of 35 (permalink) Old 10-18-2012, 09:48 PM
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DaveT319,

I like that modification and it moves the bars forward by about an inch and a half if I am looking at the pictures right. I have extra long arms and that may be an improvement for my arm comfort. Using the remaining lower/rear threaded holes I would have a nice location for a small rectangular bar and box for the switches I need to mount for my driving lights and switching between my dual headlights. Nice work. Are you going to finish off that open location in any way or leave if for a future project?

and always remember, "Ride until you rot!"
**Really not sure if the Big "C" is back right now
but having to face the fact that this is a lifetime routine
going forward. Five operations done and it still continues.

Tom
Vulcan 2000
New ride: 2009 Victory Vision Arlen Ness Signature Series
4507 miles
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post #9 of 35 (permalink) Old 10-18-2012, 10:05 PM
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If I'm seeing that right, you only have two bolts holding your bars to the bike now?

Seems a bit weak engineering wise.

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post #10 of 35 (permalink) Old 10-18-2012, 10:39 PM Thread Starter
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Quote:
Originally Posted by Vulcan2000 View Post
Are you going to finish off that open location in any way or leave if for a future project?
Nope, no plans for that area.
Quote:
Originally Posted by Knifemaker View Post
If I'm seeing that right, you only have two bolts holding your bars to the bike now?

Seems a bit weak engineering wise.
Yeah, but there's no way around that that I can think of. I've seen some risers that are a similar design (just a single bolt), so I think it'll work.

I would like slightly longer thru bolts, so I have to try to track some down.

'95 Vulcan 750 - Purchased 8/2003 w/ 21,124 miles - passed 50K 9/3/15
* VN900 seat * Daytona handlebar * Converted ACCTs to MCCTs * Relocated R/R * Drilled clutch basket * Coastered * Repainted *
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