How To: Handguard Install ( using threaded inserts )
Posted: Tue Sep 23, 2008 9:07 pm
Here we tap the FatBar end with a 5/8"NC tap, to accept the threaded inserts. Start very slow and straight, as aluminum does not self align the tap like steel does. Pull out and clean out debris every couple threads. With the bar pointing downward, whack the top of bar with your hand, and the debris will bounce out. Its OK to tap deeper than desired, as the mount screws are always on the long side. Be sure to do a final cleanout/run-in with the tap after desired depth is reached.
Tapping completed.
Blue the insert and the newly cut threads. Run the insert home and tight.
Here I pound out the grip end using deep sockets (2).
I use a de-burring bit to grind the end down to flush with the smooth bore of the grip.
Ready for install.
We do the same for the throttle tube.
Fini !
Check the outside of the tube for thinning, and make a judgement call on replacement. They get thin on the outside around the 3rd and 4th fingers, followed by cracking from the end inward.
Trial fit for depth assurance, then remove for grip install.
Apply liberal Grip Glue to grip and bar, install leaving 1/32" of bar end exposed.
Install, adjust, and tighten the crap out of the screws. Job complete.
Now go hit some rocks
paul
Tapping completed.
Blue the insert and the newly cut threads. Run the insert home and tight.
Here I pound out the grip end using deep sockets (2).
I use a de-burring bit to grind the end down to flush with the smooth bore of the grip.
Ready for install.
We do the same for the throttle tube.
Fini !
Check the outside of the tube for thinning, and make a judgement call on replacement. They get thin on the outside around the 3rd and 4th fingers, followed by cracking from the end inward.
Trial fit for depth assurance, then remove for grip install.
Apply liberal Grip Glue to grip and bar, install leaving 1/32" of bar end exposed.
Install, adjust, and tighten the crap out of the screws. Job complete.
Now go hit some rocks
paul
