Has anyone tried drilling holes on the crash bar to run the wiring for accessory on the inside? Seems simple enough to drill a small hole where the light mounts and another near the top engine guard mount where the wire would exit. If I can snake some pull-through string through, I'll have a clean look without exposed wiring and tie straps.

Anyone?

 

Interesting idea ... would look good.

 

i just bought a set of engine gaurd aux lights.i was planning on doing that to.just have to take gaurd to work and mill the slots into it.ill post pics when iam done.i think it will look very clean.that is one of my winter mods,that are on my list

 

Which ones?

 

Run hot and ground. Route the ground all the way to the battery where all of the other ground connections are.

Keep the holes as small as possible. Won't weaken the bar as much. Two small holes near the rocker boxes will be better than one large one.

Deburr the holes real good, emery cloth works for this. Jacket the wire where it goes into the bar, and from the bar to the lamp. Heat shrink works good for this.

Should make a nice install.

 

What Lee said. And shove a few inches of a length of dental floss in one of the goesinto holes, put a shop vac on the goesoutof hole, and feed it in; the vac will suck it through the tubing and out. Tie the other end to a pull string, pull that through and then pull your wires with the string. Much easier! Use a grommet on the hole and/or several layers of heat shrink around where the wires come out to prevent chafing; and seal with clear silicone.

I just added a set of those Cirius LEDs to my Tri Glide, and posted some pictures in the Rushmore section at:

https://www.hdforums.com/forum/new-r...us-lights.html



The small holes were drilled 3/32 and tapped 4-40 for the lights.



I used a small dremmel diamond tool bit back side and used that to grind down the inside edge of the holes; a small round file would work, too.