I am trying to install a set of handguards, but there are steel plugs welded into the handle bar ends.
Any suggestions on how to get those plugs out?
Craig

 

leave them in and tap them. Then use that for the "Nut". Much better grip then the expandable nut that comes with the guards.

 

I second that. Drill/tap is much, much easier.


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I thought I would grind the welds off and remove. Tried drilling first. Wow. went very quickly. About a minute and a half per side. Took about ten minutes per side to tap.

 

What diameter drill bit did you use to drill out the weight?

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Drill size was 17/64. Tap size is 5/16-18

 

I used a Dremel with a carbide tip to take out the spot-welds. 5 Minutes each side, and I was done!

 

My bad, I thought you were saying you drilled the entire weight out... The side I drilled the weight out took about a 5/8 drill bit and the bar got so hot it melted the grip glue.

 

I happened to have the correct tap for the bolts that come with the tusk guards that I received today (8MM x 1.25). I drilled the hole out and started tapping. I was taking my time and I broke the tap off in the plug...GRRR.

So now, I'm probably going to go buy some dremel stuff to grind the welds off. I'm kind of bummed, I was liking the idea of keeping the weights in there because the bars aren't vibratey now as it is and I'm scared that it will get bad...

 

tap extractor? round 2?