Have a 2005 FLHRI...took off the 16" Ape Hangers and cannot seem to find any Buckhorn style bars to replace them! I ordered some Flanders 5902822 at Dennis Kirk, the holes were entirely too small to get the second set of wires through without damaging the wire pins. So, I see some buckhorns that says they fit my bike but none of them have holes punched out for internal wiring! Has anyone out there found a solution for this? Here's a pic of ape hanger holes compared to buckhorn holes.

 

Get your dremel tool out and make the hole the size you need. just be careful not to take to much material off and no sharp edges.

rk classic.

 

Ya, and here I have a son with a milling machine...he made the hole bigger which should work now...thank you for your feedback!

 

Just how good are you at soldering wires together?
The bars with the smaller hole look to be a thinner gauge of metal , least to me they do .
I would be concerned about how much material is to be removed to get the terminals through there. I'm guessing your call them wire pins correct?

When I ran into a similar dilemma I soldered wire extensions so that the wiring coming through the bars and out the hole only had cut wire ends to get through.
Reinstalled the terminals in connector and soldered connector wires to the extensions.
Lots of extra work doing this way but at the time _____ hell it worked.

One thing I worked at real hard was to have Small Smooth clean solder joints and use shrink tubing to seal up joints.
Electrical tape ain't gonna fly in this kinda repair

WP

 

Ya, I checked it...the metal is plenty thick enough...fact it even looks thicker than the Ape Hangers...

 

Sounds like you have it figured out but did you look at fat baggers inc? Their bars are 2 piece and I had no problem running the wires through when I put them on mine.