This is how I built my 12:00 bar for my Z400.

Step 1

I wanted to cut off my stock grab bar at the point just before it starts to make a 90* bend. So I used electrical tape to mark this spot. I used a tape measure to make sure both cuts were even.



Step 2

Now that the 2 tubes are open on the subframe, I figured now would be a good time to re-enforce the subframe. I drove an 18" length of 5/8" threaded steel rod into each tube on the subframe. I used the threaded rod because it was the best fitting rod I could find. I had to hammer it in, so there is no way it's going to move around in there. Here is a pic of one of the rods partially in.



*****NOTE*****
Do NOT use 18" of threaded rod unless you plan on destroying the mounting tabs for your battery hold down!!! I did not pay enough attention and I ended up blowing out the tabs! This can be avoided by using a 12" length of threaded rod instead of the 18" length! I ended up just drilling and tapping the rod and bolting my battery hold down straight into the rod.



Step 3

I left about 2 1/2" of rod sticking out of each subframe tube. Then I cut two pieces of 3/4" steel tubing, 3" each and fit them over the 5/8" steel rod. You will need to use a grinder/sander to smooth out the threaded rod because the end will have expanded from all the hammering. Smooth it out just enough so you just fit the 3" length of 3/4" steel tubing over it.



Step 4

Weld the 3/4" tubing to the subframe tubing. All the way around.



Step 5

At this point I did a few scrapes in the driveway to get the right angle on the tubing.



***Sorry No More Pics!!***

Step 6

Next cut a piece of flat steel. I used some 3/16" X 2" flat steel. I cut it to a 12" length. I held the plate up to the two tubes and marked where they meet up on the plate.

Then I used a 3/4" drill bit to drill out the steel plate in the correct location. You may need to use a reamer to make the holes just a little bit bigger, but don't go too big, you want this plate to fit nice and snug over the tubing. Fit the plate on the tubing so it is at the same angle as the tubing was scraped down to. I left about 1/16" of tubing sticking out past the surface of the plate. At this point I put a little tack weld on each tube to hold it in place. Stand the bike up on it's bar. At this point it should be pretty close to dead on, but use a hammer to persuade it to the point the plate is parallel to the ground. When you are happy with it, put the bike back down and weld the plate to the tubing, all the way around on both sides of the plate.



Clean up the welds and paint the bar! You’re done!

 

how long have you had the 12plate on? how is it holding up to the abuse? anything you woulda done different?

 

I have only had the plate on about a week, I have slammed it pretty hard a couple times and it hasn't moved at all.

If I could do anything different....

Use two 12" pieces of 5/8" threaded steel rod instead of 18". So my factory battery tabs would still be with us.

I would have cut MORE of the stock grab bar off. I would have made the cut on the other side of that flag mount thingie. One less thing for your feet to get caught up on.

I would have left more threaded rod sticking out of the subframe. And when I cut the 3/4" tubing, I would cut it the same length as the threaded rod I have exposed.

And a final step is going to be adding another plate to this one. A replaceable plate so when I grind it down I can just bolt on another one.

Bill

 

grind the flag hole off

thank for the info holmes... and BTW...nice welds! real clean

 

thats super

Looks real nice...if i get a Z thats definately what im gonna do..solid setup

 

that thing lookes like it would cut the **** outta ya if you had a mishap... does look strong tho!

 

Yeah,

I think I may radius the corners, they are a little pointy

Bill

 

Looks nice. What type of tubing did you use??? And why did you drill the tubing through the plate and not just weld it to the bottom of the plate??

Thanks

 

im not bill, but i have a idea on why he did that...i think he plans to add replaceable scrape plates when they wear down instead of the bar wearing down..that way he could have something to mount the removable plates too..thats my idea anyways

 

i know this is an old thread. but is there any way you can repost the pics? or at least send'em to me? i'm gonna be doing a scrape bar on a KFX400 this week and would like a point of reference. thanks!

 

Sorry man, I took a look around and I don't think I have those pics anymore. You might want to try Jimmah, I think he has a word doc with the pictures embeded.

Bill