Okay, so I got my bar end mirrors in the mail today, and I hit a snag. I could use advice on which plan of action I should take.

These are the mirrors:



The problem Is the inner diameter of my aluminum clipon bars are too small for the rubber expansion bushings.

Inner diameter : 15.75mm  Rubber bushing diameter: 17.5mm

To remedy this I see 2 possible methods.

1. Bore out the handlebars to fit the rubber.

2. Buy and cut a piece of rubber hose that is smaller to fit the diameter.

The second method is preferred for me since I dont have the tools to do the first. Just wondering if there is anything special about the rubber that came with. It looks just like thick fuel line hose to me, and so I figured I could jsut buy a short segment of line, cut it, replace it and be done. Any reason this wouldnt work?

Alright, so I manages to solve my bar end mirror problem by narrowing the rubber down. Also went and picked up a bi-xenon angel eye HID headlight from craigslist. got it hooked up and working.

Low Beam


High Beam

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Now I just need to make up a mounting setup for it. Also for the wiring I ran the main power from the battery along the main harness with zip ties up the right side of the bike through the triple. The length was perfect. NOW I just need to figure out where to mount the HID ballast and how to conseal all the wiring that normally would go in the headlight bucket. This is where a faired bike would come in handy.

 Nice progress, but i think your mirror is facing the wrong direction 

 

Quote from: wayne242 on March 18, 2013, 04:56:47 PM
Nice progress, but i think your mirror is facing the wrong direction 

Yep - you can tell by the bolts on the 89's. They are away from the rider, on the forward side of the clips.

Quote from: wayne242 on March 18, 2013, 04:56:47 PM
Nice progress, but i think your mirror is facing the wrong direction 

Yes they are. I put em on real quick to see how I liked them. The bushings aren't tightened all the way. And they fell. Still pulling the top apart again to paint which is why my controls aren't hooked up at all.

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So, woke up to see this out my window. I'm getting real tired of your shaZam! Michigan.


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Looks an awful lot like what I saw this morning...except it was dark still when I left for work so the blowing shaZam! was illuminated only by street lights & headlights.

[threadjack]

I'd like to officially remind everyone that the MINIMUM legal speed on Michigan's limited access expressways is 45 mph. So, getting into the fast lane and slowing to 35 is UNACCEPTABLE in anything short of a full-on blizzard or hurricane-forced downpour!   If you're that worried/paranoid, stay to the right in that whole big long string of other worried/paranoid drivers....or better yet, get the f%$k off the expressway and take the secondary roads. Not that there are many people here from MI...but I needed to vent.

[/threadjack]

Ahhh I'm liking the headlight. Cant wait to see how it sits on the forks and with the dash and clipons. Really great additions.

OK. So I found out that I lose my job in 2 weeks. Therefore, the sonic springs I planned on buying are on hold. The reason I bring this up is my headlight. In have it mounted using the stock ears, and I am concerned it sits too low for the stock front springs. What do you guys think?



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Finally got the Angel eye ballast wired up.





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I am definately buying one of those.... Changes the whole look of the bike!

Quote from: mustangGT90210 on April 03, 2013, 08:33:05 AM
I am definately buying one of those.... Changes the whole look of the bike!

They even have them in yellow 

Finally, finished my bondo work. Primed, sanded, and PAAAINT!!! Tank is done. There were a few tiny dents I couldn't see until priming, but they were small enough, I decided I didnt care enough to deal with more bondo. Below is a pic of the tank hanging and drying.

For the first time in a bit, I made some progress. 
Went through all my wiring, now things like the starter motor, tail lights, indicators, turn signals actually WORK again.
Cut the ends of my grips and installed my bar end mirrors.
Recharged the K&N drop in.
Traced out my fenderectomy.
Then I put the recently painted tank on the bike, dropped in some fuel and started her up for the first time since November. She started right up like it had been only a couple days. 
Cut the headlight mounts to fit the HID headlight (paint to come soon)
Rebuilt my gauges witht he new dampers, and LED's


What's left until my project is finished (for this season anyway):

Paint and clear my plastics and front fender once I get the paint. 2K clear came in 
Paint and install gas cap.
Swap out my front master cylinder with one from an 89 and bleed the lines.
Figure how I want to mount my integrated tail light.
Drink beer and rejoice.

How it is currently sitting (sorry for bad pic. I take a new current pic next time I get it outside)

That headlight is great. can't wait to see the finished project.

Where in MI are you? I am north of Lansing.

That things coming along great, really liking that blue

Thanks, I wanted to paint the headlight blue as well, It's easy to take apart, 4 screws and done. Problem is I have had a lot of problems painting plastic in the past. As I understand its because of the release agent used in the molds. So instead of possibly making it look terrible I will just leave it black to match the frame.

quick note on that blue paint, puma, if its the metallic blue rustoleum i think it is, i used it, and my buddy used it on our projects. IT NEVER FULLY CURES EVER

any time a single drop of gas hits it, it runs, the flakes all scurry around, it sucks.
Make sure to get a very good, full & thick layer or clear coat on that stuff.

You've come a long way! it looks awesome!

It isn't rustoleum, but i definitely planned on it with the clear. I bought 3 cans of spraymax 2k as per a recommendation by someone on here...tombs maybe?

good stuff, tomb is a master spray-canner in my eyes, just thought i'd warn ya. I had my share of frustration with the perfect coat of paint... then i put down the gas can a little too hard and a tiny drop juuuuust makes it onto the paint. shaZam!.