![]() That means the next article will cover mounting a sprung solo seat and p-pad. 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 Vehicle Specific Exact Fit parts are designed specifically for your vehicle. 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. Burly Short Sissy Bar For Harley Sportster 2004-2022 Chrome Previously Installed 175. 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. 2003 Harley Davidson Sportster Manual 53. 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. This item: Chopper Bolt On Sissy Bar - 1994 - 2003 Sportsters 134.95 USD Notepad 1. 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. Kickback DIY Sissy Bar Kit SKU: 104-0081 89.95 74.95 Save 15.00 Free USA Shipping Over 99 Free Tech Support M-F 8am-5pm EST In stock Quantity Add to cart Pay in 4 interest-free installments of 18.73 with Learn more TC Bros. 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. 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 DIY sissy bar kit with everything you need to mount it to your Sportster chopper.
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