Tuesday, May 14, 2013
The New Hand Controls Install Part III The Grinding
New hand controls are (almost) done...
Note the big ass lip on the levers is not there any more.Neither is the push/return cable or the original switch housings.
The new hand controls are all but finished now. Final wiring was completed as the hi/lo beam was wired from the headlamp bucket, and the front brake light pressure switch from the banjo bolt was hooked in. Both went in fairly straightforward without any major surprises. Once the harnesses were reconnected, a final check revealed everything to be working as it is supposed to.
In addition to looking nice, the big headlamp bucketprovides a ton of room for the new switch.
The new hi/off/lo beam switch, in its weather proof boot.
Everything in its right place.The Biltwell Whiskey throttle was also installed. I decided to opt out of the "push/return" cable, and instead I will be running a single cable setup with the "pull/accelerate" cable only. Im sure there have been some accidents caused by stuck throttles and lack of a push/return cable, but Ill just try really hard to remember to squeeze the clutch and hit the kill switch should I ever get the throttle to stick in the open position.
The bulk of the grinding down the stock HD levers was also finished. I could have opted to just buy new lever assemblies, but, a) Id rather not spend the money, and b) they would just be new levers. For the grinding, I mounted them to the end of the old bar and went to town. If I had any advice to give, it would be to go slowly and check your progress with every little bit of progress you make. It doesnt take much to f it up and make a big gouge or take too much metal off.
There was a lot of metal involved in hooking up to the stockswitch housings, not to mention the lip on the clamp, that had to go.
Stock right hand control and lots of extra material.
It goes quickly, so if you find yourself doing this project,you would be well advised to take your time.
Once the lip and extra metal for securing to the stock housing was ground off, I couldnt just leave the rest of the lever assembly black. So, I took a small 120 grit flap wheel and a wire brush to it and stripped it down to metal. I still have some sanding in the corners to do but its definitely getting there.
I tried to smooth that edge and make it flush.
Theres still some final sanding to do but its pretty close.