Triumphrat

KAH24 · 03-27-2006

I ordered a set of Napoleon bar end mirrors for my Thruxton, and would like to drill out the solid bar insert to install.

When I searched for instructions, it appears that most just cut down the mirror vs. drilling out the solid bar end insert.

I don't plan on going back to the stock mirrors, and would like to go with the more solid/permanent install. Does anyone have step by step on how they drilled out the ends?

Thanks,

Karl

DanS · 03-27-2006

I just did this yesterday.

The hole in the bar that's tapped for the stock end cap goes at least 3" into the bar.

I started drilling into that hole with a drill bit (3/16") that was just slightly larger than the existing hole. I kept drilling with a slightly increased drill bit size each time until I got up to the size hole my mirrors needed (5/8"). I think the bars are a pretty cheap grade of cast aluminum (aluminium?) so the drilling was pretty easy, and with a perfectly centered pilot hole to start on, it was easy to keep the new bigger hole centered.

The hardest part was borrowing a 1/2" drill to use the 5/8" bit. The second hardest part was cleaning up the amazing amount of aluminum ribbons and chips on the floor of the garage.

The whole thing (minus the 1/2" drill search) took about three hours.

Have fun, and wear eye protection.

DanS · 03-27-2006

Here's the loud-handle side.

Brooksie · 03-27-2006

I used a Craftsman Industrial Duty Drill, 3/4" Masonary bit and went at it for about 1-1/2 hours. Was much easier to by Bella Corse Superbars, and better riding position too. With the Thruxton, I would get a set of aftermarket bars that will fit the position you like and keep the stock bars as spares for when you trade it on the 1000cc Thruxton if it ever comes out.

dirtyworm · 03-28-2006

The napoleons I received came with bolt, rubber grommet and mirror. I spent $4 on a 1.25mm X 8mm tap and used the bolt sent with the mirror. Cut down the rubber grommet. Added some loctite and done in less than 1.5 hours. The bars aren't cheap aluminum, they are just Aluminum. Drill aluminum fast and steel slow, it makes life easier.