Custom Sissy Bar / Strut 07 K-9

[Big Ron]

I have an idea for a custom sissy bar. I'm in the planning stages and a good buddy who owns an ornamental railing company near me with all kinds of metal stock and the tools to bend, twist and stretch willing to help me build one.

I've been digging around the pound and Metal Fab section closely looking for some specific info. Gotten close but can't seem to find exactly what I was looking for. I don't want to copy anyone's exact look but I'm leaning towards a Devils Tail theme 18" to 20"

Keeping in mine that we know BD had a safety recall issue on a run of sissy bars with a loose fit snapping bolts.

My questions are:

1. What should the total outside diameter be to include powder coat of the sissy bar where it slips into the strut? I have no idea what powder coat thickness measures too but I guess that depends how much is applied.

2. The bolt that holds the strut plug, is that the size best to use for threading the sissy bar end?

3. Those that have sissy bars stock or custom how loose is your fit before you tighten the bolts?


Thanks gang.

Ron

 

[PurpleDog]

Just came across this one; there is a tolerance spec (trying to find/remember) what it is...It needs to be snug to prevent the mounting bolts from breaking off inside the bar. Some of you might remember that there was a recall or TSB on units that were of insufficient diameter. Several of us had the mounting bolts break as described (including me).
I thought I posted the spec on here better than a yr or so back but I can't find it at the moment..:bang: From memory I want to say it was something like .670 or .680 to something, anyone remember this?