View Full Version : Crash bar supports

01-27-2007, 01:29 PM
I posted this info once before but it's been lost since the sites crash so will put it up once again. Hopefully others can benefit from this idea.
Ok we all know how flimsy the front crash bars are, especially if you've added foot pegs. I made up a set of supports to my bike to add some rigidity to them. There's a couple of advantages to adding these supports. One is no flexing the lower cowlings thus reducing chances of cracking them as some have posted. Another is in the event of either crashing or dropping the bike the bars won't fold back and cause more damage.
What I did was to purchase a pair of 1" chromed clamps, cut two strips of 10 gauge (1/8") flat stock 1" wide x 5 1/2" long, and bought 4 stainless steel button head bolts with nylon lock nuts. I used three piece clamps but other types can be used as well. Stainless steel can be subistuted with chromed or plain steel as well.
Next was mounting the each clamp to the front bars, adding the strip steel after drilling holes on each end. Then positioning the other end of the strip steel on top of the floorboards b mounting bracket. Locate the end of the hole where you can add the other bolt. Drill a hole thou the floorboard bracket and finish the install.
On the bolt that goes thru the floorboard bracket I put the button head on top. There's only a little room there thus that's why I used button head bolts ove hex head types. You'll also find it easier to drill the holes after taking off the bracket too and it also gives you more working room getting the bolt there in place.
Here's a couple of pics. I'll add a couple more later with more detail.