Wow, got myself in a pickle.

TENACIOUS T

Member
I think you could do the Allen wrench trick along with an acetylene torch equipped with a brazing tip and a wet towel wrapped around the outside of the bars . Make sure you run the flame around the stud but not to get the stud hot . Key is to drill away 75% or more of the stud . I know it's hard on tools but if the Allen or Torx is in the form of a socket . you can then use an Impact gun also !
 

scooter

Well-Known Member
The committee just held its second meeting over a cup of coffee an established new guidance

This challenge should be viewed as multi-faceted

And when finished entrants need to document

Elapsed time - overall start to finish time of project

Effort - sum of your time actually doing work related to this project. A soak in neutra rust for two days doesn’t count as effort. Driving to a machinist does

Cost - cost of others labor or your consumables. Break an e-z out cost it. Use a gallon of neutra-rust cost it
 

airblazer

Active Member
I suppose I would’ve pursued this with the handlebar set I got off eBay if they had been in decent shape. But the bars were bent and kinked beyond my interest/skill level to have them repaired, regardless if they were OEM bars. I was only after the holder since mine was destroyed. I can take better pics if someone wants to drill out the studs and straighten them for their own interests.
 

Attachments

  • 52F3A662-3191-4527-B8AD-1CEE875E78A0.jpeg
    52F3A662-3191-4527-B8AD-1CEE875E78A0.jpeg
    882 KB · Views: 71
  • D8E80299-4142-4A65-AEA2-7CF3970CDB57.jpeg
    D8E80299-4142-4A65-AEA2-7CF3970CDB57.jpeg
    868 KB · Views: 93

cjpayne

Well-Known Member
I suppose I would’ve pursued this with the handlebar set I got off eBay if they had been in decent shape. But the bars were bent and kinked beyond my interest/skill level to have them repaired, regardless if they were OEM bars. I was only after the holder since mine was destroyed. I can take better pics if someone wants to drill out the studs and straighten them for their own interests.
Try the process I described on these. It should work.
 

69ST

Well-Known Member
The committee just held its second meeting over a cup of coffee an established new guidance

This challenge should be viewed as multi-faceted

And when finished entrants need to document

Elapsed time - overall start to finish time of project

Effort - sum of your time actually doing work related to this project. A soak in neutra rust for two days doesn’t count as effort. Driving to a machinist does

Cost - cost of others labor or your consumables. Break an e-z out cost it. Use a gallon of neutra-rust cost it

Good overview.

I know of a few people named "The", but no one with the surname "Committee". Anyone who cannot use a drill would have to farm-out the repair. Below is all documentation needed for this repair.

Drilling the remnant, then installing an m8 Helicoil...about 5 minutes, working slowly. Plus the cost of a Helicoil. Clean, new, threads quickly & inexpensively.


Attempting to drill & recut threads w/o Helicoil...approximately the same amount of time & effort. You'd also save the cost of a Helicoil.
 

cjpayne

Well-Known Member
I suppose I would’ve pursued this with the handlebar set I got off eBay if they had been in decent shape. But the bars were bent and kinked beyond my interest/skill level to have them repaired, regardless if they were OEM bars. I was only after the holder since mine was destroyed. I can take better pics if someone wants to drill out the studs and straighten them for their own interests.
If you will send those to me, I will do a step by step(with pics) thread on the process I described. Then we can all vote it to see if its worthy of a sticky in the tech area???
 

scooter

Well-Known Member
Need someone else to step up as The Committee as I want to enter the following but would have a conflict of interest. Pulled these two out of my stash. First go would be an attempt on the one on the right
image.jpg
 

allenp42

Well-Known Member
I don't have a before pic but it was typical. Here's what I did prior to breaking the studs:

Washed out inside, filled inside with evaporust and replaced with new sauce every day or 2. Did this 3-4 times. Rinsed with acetone then loaded up inside with PBlaster. Clamped in vice and taped on the ends several times a day for about a week or 2.

Ended up twisting off the stud flush on both bars. A machinist friend of mine was "confident" he could get 'em out. My bet was that he could not. I won the bet. Drilled out to 17/64" and re-tapped to M8 x 1.25.
 

Attachments

  • IMG_8533.jpg
    IMG_8533.jpg
    1.1 MB · Views: 63
Top