However, I am leaning towards using the rear P-pad mounting holes as the connection point, so I am going to hold off until I lay out the seat mounts. To finish installing the sissy bar on the chopper I still need to attach the sissy bar to the rear fender. The final step was to tack everything up with a TIG welder and do a test fit.
Step 4: Tack the Handcrafted Custom Sissy Bars on Chopper This layout won’t totally hide the wires, but once the sissy bar is chromed and the wires are covered in white shrink wrap, they won’t be too noticeable. Next, I laid everything back out on my plywood and marked the diagonal bars at the places where they lined up with the holes in the taillights.įinally, I drilled the diagonal bars as well as cutting shallow channels going from the hole towards the taillights. Then I modified the taillights so instead of just having a hole at the bottom for the wiring to exit, they also had a hole at the top. In this Harley Davidson sissy bar installation, to hide as much wiring as possible, I chucked up each diagonal bar in a lathe and drilled a 5/16” hole all the way through the center. Hiding the wires to provide added style for the chopper The final step was to drill out the 1/2”-13 threads so that the sissy bar could just plug into the new mounts.ĭiagonal bars cut to length and coped. Once the piece was secured in the lathe, a cut a 7 degree taper to smooth out the transition from the 1” rod to the ½” sissy bar. By tapping the ends, I could then screw a 1/2”-13 bolt into each piece which was used to hold the piece in the lathe chuck for the next step. Then it was back to the lathe to drill and tap a 2-1/4” deep hole into the center of each piece. While they were still clamped, I drilled and threaded the flat to accept a 3/8”-24 stud. Choose your luggae carrier at section LUGGAGE CARRIERS and rear cover in SISSY BAR ACCESSORIES. Luggage carrier and chrome cover plate (10) are a option and are not included in price. Then I clamped each piece into the milling machine at a 7 degree angle, to match the angle of the sissy bar and cut a ½” deep x 1-1/4” wide flat onto the end. All EMP sissy bars are produced by nice steel tube round 22 mm, finished with beautiful curves. I rounded one end of each piece on the lathe to match the rounded ends for the frame tubes. I started with a piece of 1” diameter mild steel rod and cut it into two 4” long pieces. My goal was to mimic the look of the frame tubes which are welded to the axle plates as well as hiding the fasteners. I decided to customize my kit by fabricating some different mounts to attach the custom sissy bar to the frame. Step 1: Custom Made Sissy Bar to Fit Your Bike
The sky is the limit when building your custom Harley Sportster. They are lightweight, reliable, and there's a wide selection of aftermarket accessories available for them. DIY sissy bar kit with everything you need to mount it to your Sportster chopper. Harley-Davidson Sportsters are a great choice to build a custom chopper or bobber for many reasons.
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