Threaded bar end inserts

Good info/video! 

I don't run any bar ends or wraps, but if I did, threading is the way to go!

That was a  good video. Thank you. 

I’ve never ran bar inserts myself and, had  a question. I’m running an aluminum Pro Taper throttle tube. What do you think would be the best way to open the end of the tube up? My first thought is to grab a pair of tubing cutters and, cleaning the inside lip up with a Dremel.
I have step bits as well.  
 

Any advice appreciated. Once again, thank you. 


 

Like Woody said, pilot hole, then a step bit.  That’s how I do it with mine for the aluminum bar ends or full wrap hand guards.

Awesome man. Thank you!! I figured with the aluminum tube it would not eventually crack like a plastic one. I just figured I could use a little advice because the last thing I want to do is screw up a $50 tube.  I will get started on it once I receive my parts. 
 

Thanks for the response Matt. I appreciate it. 
 

I forget which brands I've used but main suggestion is to make sure you got the big tap wrench as it gets pretty tough to turn towards the end. I don't know if I would trust an impact/drill to tap them or if it would strip it out. 

Well, I finally got around to drilling out my aluminum throttle tube. It took a bit longer then I would’ve liked but, I’m in a sling so I can’t expect much. 
I started off drilling a small pilot hole. Next I used a step bit. After the step bit, I switched over to the only other bit I had on hand that was carbide. 
After taking out as much material as possible, I switched over to a sanding bit to smooth the inside of the tube out. It was a bit time consuming trying to smooth the inside edge out. 
 

After cleaning up the inside edge, I beveled the outer edge using my dremel with the sanding bit. 
I cleaned everything up with contact cleaner and, installed the tube. 

Finally, I can install my hand guards. Not!!!

 After installing the clutch side, I went to install the throttle side. Somethings wrong!! Why does this bar look wrong? I was shipped two left bars. Both were for the clutch side. So, looks like I’ll be contacting Motosport in the morning to solve this.  
 

Hey, at least the throttle tube is installed.  I was so happy thinking I’d get these done today. 
Stay tuned 😂 

I finally got around to getting my hand guards installed. Been playing with other areas of the bike.  Though they weren’t threaded bar inserts,  getting the routing of everything sorted took a little figuring out. The bars feel a bit busy but, I’m still happy with how they turned out. 
 

I had a question for you. Have you ever seen Flexx bars ran with full wrap hand guards? I looked around quite a bit and, the only thing I came across was a video on YouTube. The guy trying to install a kit that adapts/accommodates  Flexx bars failed as the adaptive mounts didn’t line up with the mounting brackets. Have you heard of or, seen them successfully mounted?
 

Dealing with a shoulder injury, I’m leaning towards getting a set in the near future. 
 

Anyways, here’s pics of the install and, my project I’m setting up for off-road/single track. 
Happy New Year to you. 🍻