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Old 05-06-2014, 07:48 PM   #1
AdvRonski OP
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Joined: Feb 2007
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Crash Bar Lite- Lose 10 Lbs Without Going on a Diet

I've noticed inmates here have varied opinions on using crash bars. My 2004 came with SW Motech bars, which are plenty beefy, but pretty heavy.
I thought there should be something I could come up with that fell in between the full-boat crash protection of the SW Motech bars, and running with naked fuel tanks.
I weighed the Motech's and found they were 14 lbs.-



I fabbed a set of shorty crash bars from 6061 aluminum tubing-





One of the things that bugged me about the Motech bars was how they ran right across the screws that fasten the lower end of the upper fairing pieces to the fuel tanks. I just left those screws out, but I like the extra support they provide to the fuel tanks.







They weigh 4 lbs, for a loss of 10 lbs, and admittedly a loss of some protection. But still better than running without any bars.
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Old 05-06-2014, 08:05 PM   #2
Chuckracer
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Very Nice!! You could probably sell a few sets of those.
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Old 05-07-2014, 04:28 AM   #3
chippertheripper
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Radical!
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Old 05-07-2014, 04:49 AM   #4
Vicks
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Noice !!!

i'd have bought a set in a jiffy If I still had my 990S.
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Old 05-07-2014, 06:15 AM   #5
gearheadE30
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I'm curious to hear how they hold up in a crash or something. I've actually bent my SW bars on rocks before, and I would think it would be even easier to do with aluminum. That said, those look great and I really like that they don't cover those damn screws! Whoever designed the SW ones really missed the boat there.
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Old 05-07-2014, 06:26 AM   #6
Jaimoto
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You just can't stop fabbing cool stuff, right? Very nice bars
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Old 05-07-2014, 07:47 AM   #7
AdvRonski OP
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Thanks, guys.
Yes, I can't seem to stop making things. I usually blame it on the long Winters here, but maybe it's some kind of addiction. It has been a lot of fun, imagining something, then firing up the welder and the bandsaw.
Now I just need to get out there and ride the damned thing.
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Old 05-07-2014, 08:52 AM   #8
Off Road Ryder
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Those look great I was always a fan of crash bars but have the same issues you do. Recently I completely redid my bike making it all pretty, and much lighter, I didnt install the crash bars back on due to the weight, well in 3 rides(races) my bike now looks far worse than it ever did before, not to mention damn near puncturing a tank.. crash bars are good.
how about making a few more??
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Old 05-07-2014, 09:02 AM   #9
sonoran
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Wow those look great.

Nice work!
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Old 05-07-2014, 07:51 PM   #10
AdvRonski OP
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Quote:
Originally Posted by Off Road Ryder View Post
Those look great I was always a fan of crash bars but have the same issues you do. Recently I completely redid my bike making it all pretty, and much lighter, I didnt install the crash bars back on due to the weight, well in 3 rides(races) my bike now looks far worse than it ever did before, not to mention damn near puncturing a tank.. crash bars are good.
how about making a few more??
I'm not excited about making more of these right now. I only have very basic equipment, a pretty cheesy tube bender, and basically formed these freehand.
Getting the 2nd one to match the first was kind of tough, and not entirely successful. Also, I really don't know how much abuse these can take, and I would be uncomfortable charging someone for an untested product. The tubing is 6061-T6, but has to be annealed to bend without cracking.
More than anything, it's just fun time for me in the garage.
Now I want to get out and ride.

First, though.
I made a mudflap for the Motech crashbars to stop mud from filling up the space above the battery box and below the front cylinder-



The first muddy ride after the high fender install left a good 5 lbs of mud in there.
So, I fabbed a flap for these bars-



Now it's time for some crash testing.
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Old 05-08-2014, 01:53 AM   #11
AliveDK
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Epic work mate
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