Drilling holes in ProTaper aluminum handlebars? Safe?
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Thread: Drilling holes in ProTaper aluminum handlebars? Safe?

  1. #1
    Senior Member kj7687's Avatar
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    Drilling holes in ProTaper aluminum handlebars? Safe?

    I would prefer not to grind the indexing tabs off of my throttle control mount; I would prefer to drill holes in my new ProTaper SE bars so that the tabs can still fit in there and prevent the throttle from rotating on the bars. At this point, I'm fairly certain that a couple of roughly 1/8 inch holes (I haven't measured or anything yet) will not cause any significant structural integrity issues that I should be concerned about. So I'm pretty much planning on doing this. I just wanted to see what you guys think. I should note that I will have very strong HDB Ultimate handguards on the bars, which will connect from a bolt-mount on the end of the bar, to bolts mounting the other end of the guard to the handlebar top clamp. This of course should add structural integrity to the bars. So all things considered, I don't think I would ever need to be worried about the bars breaking - at least surely not unless I have a serious crash (as in, not while I'm riding the damn thing...). So anyway, let me know what you think people, thanks.
    KJ, just KJ, ok.


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  2. #2
    Senior Member methamphetasaur's Avatar
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    I say grind off the tabs, it's much easier. That's what I did when I replaced my bars. Both of the pieces with tabs can now be moved by hand even though the bolts are as tight as possible, but you really have to force it on purpose; it's not like they move when you hit the killswitch or anything. I seriously doubt drilling holes would weaken the bars in any significant way, but it seems to me like more work than it's worth.

  3. #3
    rbm
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    Senior Member rbm's Avatar
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    It won't be a problem to drill the bars for the tabs.

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    Super Moderator littletommy's Avatar
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    Either way will be fine, both methods have been used here before.
    1st John 1:9
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    John 3:16
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    Senior Member kj7687's Avatar
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    Okay thanks for confirming, guys. This is what I was thinking. Even with rubber or electrical tape to help stop the control from sliding, it drives me crazy. I ground the tabs off for my KLX setup, and I can't stand it that way. I want to know that I can yank back on the throttle HARD and hang on tight, and it's not going to go anywhere.
    KJ, just KJ, ok.


    Current rides:
    2004 GMC Sierra 1500, 1999 Toyota 4Runner

    Past rides: 2015 Yamaha XT 250, 1997 Suzuki DR 200, 2007 Honda Ruckus, 2007 Yamaha TW 200, 2007 Kawasaki Ninja 500, 2009 Kawasaki KLX331S; 1994 GMC Sierra 1500, 1987 Nissan Pathfinder, 1992 Acura Integra, 1986 Honda CRX, 1989 Jeep Cherokee, 1994 Chevrolet Astro Van, 1979 Volkswagen Rabbit, 1984 Jeep Cherokee

  7. #6
    Senior Member Devils Advocate's Avatar
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    Quote Originally Posted by kj7687 View Post
    ....

    I want to know that I can yank back on the throttle HARD and hang on tight, and it's not going to go anywhere.
    HellOoo, This a TW200, not a Saturn 5 rocket.
    littletommy and Turtle Chaser like this.

  8. #7
    Super Moderator littletommy's Avatar
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    A couple 1/8 inch holes won't matter.
    1st John 1:9
    If we confess our sins, He is faithful and just to forgive us our sins, and to cleanse us from all unrighteousness.

    John 3:16
    For God so loved the world, that he gave his only begotten Son, that whosoever believeth in him should not perish, but have everlasting life.

    John 3:17
    For God sent not his Son into the world to condemn the world; but that the world through him might be saved.

    Hidden Content <<<Click here. Hidden Content

  9. #8
    Senior Member Turtle Chaser's Avatar
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    Quote Originally Posted by kj7687 View Post
    I want to know that I can yank back on the throttle HARD and hang on tight, and it's not going to go anywhere.
    Quote Originally Posted by Devils Advocate View Post
    HellOoo, This a TW200, not a Saturn 5 rocket.

    Well, "it's not going to go anywhere" quickly

    MAC
    Last edited by Turtle Chaser; 09-20-2015 at 12:03 AM.
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