Continue to run into folx who ask about the mirrors on my bikes. Most are surprised I made them (commentary on my skills or post mod consumer society - you choose). If you've got $15 bucks, basic tools and 20 minutes to spare you can have trick mirrors. Plenty of people have done this, here and elsewhere - but I've never seen a how-to. I was doing another set this morning, so here's a walk through of my idiocy since its the video game age. Yea, most of you can mill this out of billet, but seeing the questions I've had, there's a few around that it might help. My chance to give back a little. If you're accident prone - have mate do it.
(1)Supplies
Here's what you need more or less - a PBR helps but didnt make the shot.
Self explanatory, particulars below - you probably have all this stuff, if not someone you know does - borrow it
[INDENT]Third Eye Mirror - sourced from Ebay, Amazon, etc - @ $12-16 shipped[/INDENT]
[INDENT]1/16" x 3/4" Flat Aluminum Bar Stock - Lowes, etc - @ $3
[/INDENT]
[INDENT]1/4" Drill bit[/INDENT]
[INDENT]#8 (7/8" bars) or #12 (1 1/8" bars) Stainless Steel Hose Clamp[/INDENT]
[INDENT]An old bar or round stock for forming[/INDENT]
(2) Measurements
Cut about 2 to 2 3/4 inches of the Aluminum Flat Stock - this will be your bracket. I cut long then trim back once I determine I've cleared all the crap on the bars. Less is more when your done.
(3) Bend, Round, Drill
Bend the Flat Stock at @ 1 1/4" - as far as you can get the stock into Large ViceGrips.
Cut the corners to round the points - you don't want stitches now or later.
Place your mirror on the bracket between the rubber isolators - make sure the back of the mirror is in front of the bar side of the bracket. Mark the spot to drill your hole - oops I forgot to mention a Turquoise Sharpy - pencil works.
If you have a punch - use it - really does make it easier. Otherwise drill your hole. Clamp a piece of scrap wood under the bracket so you don't drill into your counter - especially if you live in a rental - I know what a kitchen counter top costs, voice of experience here.
At this point you should have something like this - if not I wouldn't proceed - find a mate to finish.
(4) Form
Clamp the non-drilled side onto your bar with the Round ViceGrips (yea they have a real name, I don't know it, so lets not confuse anyone). While you're getting your second PBR, find some safety glasses. Use your hammer to form the bracket to the bar. This is the secret step - round = fit. Ain't pretty - but if you wanted pretty you'd be milling this, or paying someone else to do it.
You should stop when you have a radius like this - unless you're working out some aggression. If so, show the bars who's boss.
At this point, wrap the sandpaper (I had some 120 round handy - use 120+) around your bar and smooth out all the jaggies on the bar side. Your nice new black bars will thank you.
(5) Mount
Mount your clamp (they do come apart - don't take the bars off to slip them over the end - I'm not kidding) and slide your newly mfg bracket under. Sit, adjust, tighten. You are golden - and all of your friends will be amazed you can make stuff like this. I know mine were.;)
If you haven't been distracted by the other 4 PBRs (hey it's early Sunday morning - I dont drink good beer on Sundays). you've got about 20 minutes into this - and $15 not counting the beer.
This is the 5th or 6th set I've done. Its a nice way to thank folx who lent you a plug or toilet paper on the trail. Plus its nice to have mirrors you made - on your time frame.
