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Discussion Starter · #1 ·
I want to make a set of apes for my BSA and didn't know what wall thickness I should buy for this steel? I know the bars need to be 7/8", and I plan to route the wiring through the bars, if that makes any difference? Thanks, T
 

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For bars don't mess around with anything under .090-095". I would also highly suggest picking up real tubing in 4130 and using seamless tubing NOT welded seam.

Brandon
 

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i build a lot of custom handlebars
i never use anything less than .120 wall thickness
try and stick with dom tubing or 4130 chromoly or 304 grade stainless
 

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Discussion Starter · #5 ·
Cool, thanks for the advice, that's what I'm looking for. One last, where's a good place to get material? We have some steel supply places in Houston, which I'm guessing would sell seemless 4130? And is chromoly weldable with a trigger-fed Hobart flux cored/MIG welder? It's rated to 140 amps.
 

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onlinemetals.com or mcmastercarr.com or metalsdepot.com

BUT...

Your local place will be much cheaper and you can get it right away.

My local steel supply has quite a selection, yours should too. Just call em up.

1 inch O.D., DOM, with a .120 wall

.120 wall is pretty stout, but I'd like to error on the side of stout. lol
 

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Chromoly isn't going to be happy welded with the equipment you have. Regular .120 wall D.O.M. mild steel seamless tubing will be just fine.
 

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.120 is a typical thickness for frame tubing, and is overkill for handlebars.
.095 is perfect.

Heck, Harley stock bars are even thinner, made from stainless, and there are bazillion of 'em on the road.
 

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.120 is a typical thickness for frame tubing, and is overkill for handlebars.
.095 is perfect.

Heck, Harley stock bars are even thinner, made from stainless, and there are bazillion of 'em on the road.
I would honestly have to agree, but in the typical bender i've had problems with kinking in materials as light as .095.
 

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I would honestly have to agree, but in the typical bender i've had problems with kinking in materials as light as .095.
yeah the thicker wall material holds shape better in the bender and it does not cost much more for the thicker stuff
i cant really agree that its overkill at all
if your bars break u really dont stand much of a chance making it home withou being badly injured or worse

no you can not weld chromoly with a mig it needs to be tig welded
 

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Just looked at a half dozen handlebars and none of them were DOM. Most around .095. But I don't see where heavier is gonna hurt anything. It's not like you're gonna add 50 lbs. to your bike.
 

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...no matter what thickness you would use...why? because for example look the Triumph handle bar clamps, too thin in the base in my opinion, so if you crash or hit the thicker handlebar will resist but not those clamps.
Most 70 s 80 s jap bikes the clamps are from Aluminum, so I do not think that those resist a strong impact...
 
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