i have a small gap on my right side, W1's, Avon grips, hasn’t really bothered me though, black bars, black controls, black grips, not very noticeable.

 

So here are the last two emails that went back and forth.

Rex,

Well, I've emailed Performance Machine, Avon, Kuryakyn, and Joker Machine. They all note that they make their grips based on the stock measurements. Then they physically measured them for me. They are all within 1/10 of an inch.
Then I emailed a few of the custom bar manufacturers and asked about the measurements, (without giving your name, or the Carlini name) and they all responded with the same. That the bars were cut too long. When I emailed the pictures and asked of a solution, again, they all responded with the same. The bars have to be cut, noting that much gap can't be made up anywhere. 1/8" maybe, but a half inch isn't doable.
Have you been able to recheck your jig and remeasure?

Thanks,

 

And his reply this morning.

There is no problem with our jig. We have not had any customers approach with an issue with the length of the grip sections on our bars at all. This is probably due to the fact that the majority of our customers hire a certified mechanic to do the installation for them. It is normal procedure when doing an installation of bars to test fit the controls and grips prior to running the lines internally in case the grip sections need to be trimmed or in some cases, lengthened (I have seen both). It is impossible to create an 1.5" bar with a grip section that will accommodate every grip on the market. Handlebars require a certain amount of finesse in order to achieve a perfect fit and a certified mechanic can give you the proper instruction to complete the job to your satisfaction.

Thanks,
Rex

 

Does finesse=magic? Cause I think that is what it would take to close that gap..

 

I should have seen this coming. There is not one vendor out there that will even order from him, or has any relationship with him. I was warned several times about them, but gave them the benefit of the doubt after calling and speaking with them. I guess he just proved my ignorance and his poor customer service and poor quality of workmanship.