DIY Bar End Weights

[Deep6blue]

I was in the market for some bar end weights. But the products available were either too expensive for what it is, or I wasn’t sure if it would fit. So I decided to try and make my own. Plus, it’s more fun to make it yourself.

I have a 2017 XCX. These were made to help with the 4500RPM vibration. The vibration is mostly gone now; although if you touch the clutch or brake levers you can still feel the vibration. Just not in the grips.


There are a couple ways of doing this. This is version 2.

Materials
60mm * 6mm machine screw
Thick washer .75 inch
.5 inch hex cap (found in the plumbing isle
.75 inch metal spacer
Lead (sold in 1lb coils for making fishing lures)

The original screw is 40mm. The hex cap is 22mm, so we need the longer 60mm screw. The hex cap is one typically used for plumbing.


First, drill a hole through the center of the hex cap.



Flip the cap over and put the spacer and screw in.




This is the fun part. You need to heat the lead and drip it into the hex cap. Try not to get it into the spacer. Do not heat the hex cap and use it as a crucible. If you do the lead will just leak out the bottom through the hole. By dripping it into the hex cap it solidifies just enough to not leak.



LET IT COOL OFF! Air cool or dump it in water.

Then clean it up with a file or sandpaper.




Next, clean it a bit more. Then install it with the metal washer.



I painted the hex cap and washer black. Two pictures, one with flash, one without.






Overall this was an easy and rewarding project. I like the look of the hex caps over the standard round ones you see. I estimate the weight to be about 80 grams each. I keep forgetting to weigh it on the postal scale.


Version 1 was similar, except I used .75 inch copper pipe caps. They worked really well, but I painted those with Plastidip. It looked like crap. I could have just repainted them, but I wanted to try something different.

[TotnesSteve]

Nice job and good pics. Thanks.

[Deep6blue]

The bar end weights are 3.7 ounces each with the washer. Or 104.89 grams if you prefer.

[XCaTel]

Oh, damn! I was looking for ones at 105 grams!

(I'll type your reply for you  )

[moggi1964]

Originally Posted by XCaTel

Oh, damn! I was looking for ones at 105 grams!

(I'll type your reply for you  )

 

[Deep6blue]

Xcarel, I hope with version 3 to hit 105grams, just for you.   

[XCaTel]

Originally Posted by Deep6blue

Xcarel, I hope with version 3 to hit 105grams, just for you.   

Cheers!

[CaptainTrips]

I did something similar. I have the OEM hand guards and simply pounded lead fishing weights into the aluminum end caps that came with the OEM guards.

[Deep6blue]

Originally Posted by CaptainTrips

I did something similar. I have the OEM hand guards and simply pounded lead fishing weights into the aluminum end caps that came with the OEM guards.

Interesting. How much weight do you think you got in there? I'm happy with the reduction in vibes now, but this could lead to another project. Perhaps pouring the lead like I did, then removing it from the hex cap. Then sliding the form into the bar.

[CaptainTrips]

Originally Posted by Deep6blue

Interesting. How much weight do you think you got in there? I'm happy with the reduction in vibes now, but this could lead to another project. Perhaps pouring the lead like I did, then removing it from the hex cap. Then sliding the form into the bar.

I'm not really sure, but certainly a few ounces. I just tamped the lead into the space with a punch and hammer, then drilled it out for the bolt.