Delrin Handlebar risers?

[Hybridchemistry]

Alright, so I'm trying to hack on some MX bars to a Ninja 250 I picked up, and I want the universal bar mounts to sit flush on the top triple, bolted to the lower bolthole for the stock handlebar riser. On a pregen Ninja 250, without the stock risers there, there is a drop down ledge there.

Is it a bad idea to try and make a rectangular spacer out of Delrin or other hard plastic that bolts on there to give me a flat surface to bolt the universal mount?
Or should I stick to something metal, like aluminum?

If I should stick to aluminum, how bad an idea is it to cut down handlebar risers from 1" to whatever I need? If it's cut straight and level with a bandsaw it should be fine, right?

 

[DIY]

"I'm trying to hack on some MX bars to a Ninja 250"

I got nothing to help you but I like how you think.

 

[byke]

I wouldn't use delrin. You're trying to avoid drilling the upper triple?

 

[Hybridchemistry]

I wouldn't use delrin. You're trying to avoid drilling the upper triple?

Yeah, I know guys have in the past, but with some other tube spacer hack to get a nut to tighten down. This guy did close to what I want: https://www.ninjette.org/forums/showthread.php?t=106406

But I want to try and preserve the stock bolt size. The universal mounts I have were tapped to fit a regular SHSC, instead of the weird D bolt they come with. I'd like to make use of as big a bolt as I can, so I might end up drilling and tapping the stock holes. I still don't like the look of that spacer bar he has in there :nchantr

Edit:
I went to look at the bolts, and there's normally 2 bolts that hold the stock riser in place, they're like half the size that this universal mounts are tapped for. I'm starting to see why the guy on Ninjette drilled out his holes and use weird spacers.

 

[auntiebling]

Delrin might be a bad idea if it's squishy enough that the bolt can't stay tight. I don't think that will be the case but it could maybe happen.

just use a bunch of washers. Nothing says badass like washer stacks

 

[Hybridchemistry]

Delrin might be a bad idea if it's squishy enough that the bolt can't stay tight. I don't think that will be the case but it could maybe happen.

just use a bunch of washers. Nothing says badass like washer stacks

From what I've read/experienced with Delrin, it can be pretty solid, but I have no idea how it'll handle living in the elements, or if it'll put up with the bad-assery that is a rashed Ninja 250 with MX bars and ~dual~ headlights :cool

This guy drilled his top triple, I think it looks silly: http://forums.ninja250.org/posting.php?mode=topicreview&t=76181&tro=1

Again, silly: http://forums.ninja250.org/posting.php?mode=topicreview&t=38292&tro=1

 

[stangmx13]

i see no point to using Delrin. it offers little to no damping characteristics. the connection, when bolted properly, wont vibrate or rattle. and, u dont need its low friction. delrin is pretty good w/ UV and temp compared to most plastics, but its not as good as not-plastic. so whats the point? just use AL.

 

[Hybridchemistry]

i see no point to using Delrin. it offers little to no damping characteristics. the connection, when bolted properly, wont vibrate or rattle. and, u dont need its low friction. delrin is pretty good w/ UV and temp compared to most plastics, but its not as good as not-plastic. so whats the point? just use AL.

I figured I can work Delrin a litte easier than Aluminum, that's about it. If I am going to go with an aluminum spacer, I'd like it to be made with some precision.

There's probably a good reason to use a thicker bolt than the stocker, right? Now I'm thinking of having a shop drill, tap, and make spacer that'll fit an appropriate size bolt...

This guy seems to have done the conversion very nicely: http://motoinked.com/2014/03/30/part-3-of-project-ninja-turtle-300r-handlebar-conversion/

 

[auntiebling]

There is no reason to increase the fastener diameter IMO As the first thing to break is the triple as even the original fastener pulls through it in an impact scenario.

 

[byke]

I figured I can work Delrin a litte easier than Aluminum, that's about it. If I am going to go with an aluminum spacer, I'd like it to be made with some precision.

There's probably a good reason to use a thicker bolt than the stocker, right? Now I'm thinking of having a shop drill, tap, and make spacer that'll fit an appropriate size bolt...

This guy seems to have done the conversion very nicely: http://motoinked.com/2014/03/30/part-3-of-project-ninja-turtle-300r-handlebar-conversion/

I'd be worried that the delrin is too soft and your bars would loosen, but you could probably get away with it for an unknown period of time. Personally, I'd rather stack washers than use delrin. Take your measurements and look on McMaster, you may find an aluminum spacer that's plug & play. Use steel if you need a spacer for the bottom.

They did a good job in that link, maybe you could score a triple like that on eBay for your bike? It looks easier to convert and you'd have your original in case in didn't work out. Is the tube diameter the same?

 

[bpw]

Aluminum is super easy to work, even with hand tools. But I suspect Delrin or similar would be just fine as well.

 

[ST Guy]

I figured I can work Delrin a litte easier than Aluminum, that's about it. If I am going to go with an aluminum spacer, I'd like it to be made with some precision.

There's probably a good reason to use a thicker bolt than the stocker, right? Now I'm thinking of having a shop drill, tap, and make spacer that'll fit an appropriate size bolt...

This guy seems to have done the conversion very nicely: http://motoinked.com/2014/03/30/part-3-of-project-ninja-turtle-300r-handlebar-conversion/

Frankly, the difference between Delrin and aluminum isn't much when it comes to machining. I, for one, would never consider Delrin or any other plastic for the application you're talking about.

Design one, sketch it out with dimensions, and have someone machine it for you out of 6061.

 

[Hybridchemistry]

So, instead of sketching something, and bringing it to a shop to get milled or drilled, why not buy some used aftermarket risers of ebay and cut them down, or find someone with a bandsaw and get them trimmed?

Also, Pirelli Sport Demons are supposedly best tires in 16", MSS or Santa Clara Cycle cheapest for them? Or BT-45s?

 

[bpw]

Just go at a block of aluminum with a hacksaw and a small selection of files. Will probably take less time than driving to someones shop. You can move a lot of material quickly with nice sharp file.

 

[Jalopyshoppe]

I've done a few handlebar conversions, and I say drill the triple in the middle, but cut some aluminum to create a better surface to bolt to underneith. Like a custom cut washer. use 1/4" alu and it'll be fine. I have a tig machine, so I weld them in, but it's not a requirement. the outward mount like the guy uses in the first one doesn't have much surface under the risers, and that puts more stress on the bolts. Having a flat surface to bolt the riser to is the stongest method.

 

[Hybridchemistry]

the outward mount like the guy uses in the first one doesn't have much surface under the risers, and that puts more stress on the bolts. Having a flat surface to bolt the riser to is the stongest method.

That's what I'm trying to get to. Gotta figure out where to get some Aluminum now I guess.

 

[TT03gsxr]

You could get a pair of ninja 250 risers and cut them down, file, repaint. Should be flush and would be the correct height, plus would have holes predrilled.

 

[Hybridchemistry]

You could get a pair of ninja 250 risers and cut them down, file, repaint. Should be flush and would be the correct height, plus would have holes predrilled.

Thought about this as well, only thing holding me back was 1) coat of risers, eBay is stupid expensive, 2) cutting them straight seems like a job for a bandsaw which I do not have, anyone want to trade beer for a chop job?

 

[Jalopyshoppe]

I'm in Danville most of the time, and have a bandsaw here you are welcome to. It's a hike from the city, but the price is right...Drill press as well.

 

[Hybridchemistry]

I'm in Danville most of the time, and have a bandsaw here you are welcome to. It's a hike from the city, but the price is right...Drill press as well.

Damn that's tempting, esp the drill press. Not too far when I'm over at the GF's in Oakland.

Moderate news: Picked up a slab of alum that's ~1/2" thick, which is about 13mm. I needed 15mm to space. Damn it. At least it was just 10$. Currently looking for a jigsaw to try and cut it up to more manageable sizes.

https://goo.gl/photos/L6zy6cYChBEDVZJq6 it looks very close, but I don't think my caliper is lying. I think I'll just try to shim the bottom with some old inner tube, and maybe another slip piece between the mount and spacer, call it 'vibration dampening.'