If anybody has access to a machine shop or can help me machine out a very basic part for my GS I'd REALLLLY appreciate it.  All the shops around here (Santa Monica/LA) say they will charge 100+ for something that it looks like will take about 20-30 min to do.  I'm more than willing to pay but I'm kinda poor (college student) and $100 seems pretty steep.

The 'basic' part is the handle bar raiser template except on 1/8 inch thick aluminum metal.  so its a sheet of Al with 2 beveled edges and 8 drill holes.  I'd do it myself but dont have a 37mm drill bit nor do i know how to bevel edges with a drill.

Thanks for any help any of you guys/gals can provide

bevel can be done with just touching the hole with a drill bit 3-6 sizes bigger than the hole
the 37mm holes...1.46.....1.5 inch hole saw

bevel edges on the outside of the AL. plate .... FILE

draw it in auto cad or by hand on a piece of paper
lay on AL plate
and center punch the important holes

Can you draw me a picture or something?  I don't see why you need to cut 37mm holes in a bar riser...

You can buy a chamfer tool for probably less than $10.  American countersunk screws are 82 Degrees included angle.  Metric countersunk screws are 90 to 100 degrees, depending on the diameter.  It does a much better, cleaner countersink than using a larger drill, which usually has an included angle of 118 or 135 degrees, depending on point style.  Probably more info than you wanted, but at least they are cheap. 

Using a drill to countersink 1/8 material will probably grab real bad when the drill breaks through.  (I am a machinist). 

You are talking about countersunk holes when you say beveled edges, right?  Or are you talking about the edges of the parts? 

hey werase sorry for the dumb question but what is autocad?  seems to be some sort of program that is hooked up to a machine and if it is where can you usually find these other than a machine shop?  I'll look for hole saws at home depot, thanks for the tip...

makenzie...the 37mm are for the forks to slide thorugh...i'll borrow my friends digital camera to take a picture if you like but it's basically a top view of the handle bar raiser except in much thinner Al

corndog..i'm looking this stuff up on wikipedia right now beacuse i'm really sorry but you lost me pretty good there.  i know physiology pretty well though if you're really good at analogies 

yeah I'll have to see a pic because I have no clue how you intend to raise the handle bars with a thin aluminum plate.

We need to see a pic or a sketch and a description of how the part will fix to the the bike, the description is confusing.  Most machine shops charge by the hour over here and I cant see it being any different over there. You might get a better deal if you can find a small backstreet place and offer to pay cash without a reciept.

Time + Material, and 100 bucks isn't too bad.


When you say "Sheet" of aluminum, how thick of a sheet are you talking?  .071 inches or thicker?  .25?


what are you trying to accomplish with your project/modification?

i mean 1/8 of an inch thick and what i'm trying to do is get this piece so i  have something to attach my speedo/tach to...on the stock 04 gs the speedo and tacho are bolted into the handlebar raiser.  I have clip-on's now so i have no need for the thick old bar raiser (yet) and i want to repalce it with the thin piece of Al so i can simply reattach my tacho and speedo...

PS...clip-ons are far more brutal on the balls of your hands and forearm muscle tension in packed fwy taffic...but in every other category i think they beat out the old upright handlebar..

if your clips are hurting your hands you're not doing it right.  You need to support your body with your back, hips and abs...not your hands and arms.  They are for steering. 

Handlebars = not a load-bearing structure.

So I think that he is attempting to make the upper triple tree clamp less the attachments for 89' style clip ons, and wants the ears to have soemthing to mount the dash to. He needs the countersink(bevel) to recreate the the features of the ears to mount the dash.

See Below pictures(it so sexy and freshly painted, I will install this weekend after I make some new bars)

Why didn't he say so?  He needs a bracket for the gauges.  Isn't the big chamfers on the holes for a rubber mount for something> 

Yeah a rubber peice with the same profile goes through there