If I think about something long enough, the solution comes to me. Case in point: I got bar-end turn signals from Oberon, specifying the version for 1" bars. But when I tried to install them, the collets (the part that expands inside the handlebar) wouldn't go in. Head smack. The collets were designed for steel bars, which have thinner walls than aluminum bars.

My first thought was to bore out about an inch of the end of the bars with my stepped bit. That didn't work for various reasons.

I emailed Oberon to find out about getting just the collets for 7/8" bars. They never answered.

Okay, I could make the brass collets smaller. But how? I could get a friend of a friend to turn them down on his lathe. But that would mean calling in favors I didn't have and waiting for him to get around to it. Or I could shop around for a machine shop willing to do it at a price I'd be willing to pay. Mmmmm, maybe as a last resort.

Then a possible solution came to me as I was going to sleep last night. Ah-ha!

So this morning I disassembled the collets and chucked them up in my drill. Then I held the spinning collets to my spinning angle grinder. A few seconds of grinding on each and, presto, perfect fit!

A bottle opener would go great there.

MotoBuddha wrote on 11/15/11 at 13:01:51:


See, that right there is a great idea.

Had another senior brain fart moment. I had the wiring harness all worked out, except..... Where the hell is the connection for the headlight? I had myself convinced I was missing a length of wiring and a couple of connectors. I was cussing and fuming. But then I poked around on the bike and, doh, found where I'd tucked the necessary connector temporarily out of the way. Head smack.

that is awesome.  not many people take that much pride in their work anymore.  at least you know it is being done right

Thats gonna be one purtee thang..

shes gunna be purty