I just got this mounted this evening and tried them out :
I used to have an HD 883 Sportster with a set of these mounted. I paid over $40 US for the set nearly 7 years ago. These were constructed from stuff I found solely at Lowe's for a total of 25 USD not including tools and locktite(you can use a tube so many times.) Here's what you need :
2 - (5/16)" nuts
4 - (1/4)" flat washers
2 - 2" x (5/16)" hex head bolts
2 - 2" x 4" angle bracket(1/8" thick galvanized) from lumber area
2 - 3" x (5/16)" hex head bolts or metric equivalent. These replace the stock frame to crankcase bolts so if you ride off-road much or jump any, be sure to get high-quality bolts that are same diameter as the factory metric bolts. Mine were slightly under but I ride easy 90/10.
4 - (1/4)" flat washers or metric equivalent
2 - (5/16)" nuts or metric equivalent
1 - 1" x 3' perforated steel tube or they have a 1.5" or 2" I believe, if you like the fat look. 1" is more than strong enough
TOOLS
*A drill and bits for steel up to diameter of bolts, maybe a little over. I gauged mine by the holes in the tubing and never looked at the size marking, sorry.
*Hack-saw or carbide blade in a SkilSaw.
*Wrenches/Ratchets
*3"+ C-clamp for drilling
*Sharpie
*Carpenter Square
*Blue Temporary Loc-Tite(should have it for your dual-sport anyway!)
*A loving wife to allow the use of her kitchen! (or your own workshop)
NOTE: There's a short bolt and its nut/washer in the photo that I didn't need because the angle brackets fit the XT frame so perfectly. The bolt was intended to stabilize the brackets from pivoting and stressing the other bolts.
I used a few zinc plated nuts and bolts, but in hindsight I should have gotten all galvanized. I didn't realize Lowe's carried galvanized parts in such a variety until my second visit. These bolts positioned right behind the front tire and catch all kinds of weather. Just look at the stock bolts after only 2700 miles.
To Begin:
Remove the factory bolts and make sure your brackets fit properly. The bolt holes should be pretty close to the edges of the brackets since you don't want the brackets mounted too securely in the event the bike lands on them. I'd much rather tear the brackets off than tweak the frame or crank case! The brackets I used are flexible enough that I think they will bend in that event. I also plan to cut flex points into the bar to help it bend and absorb the energy of a crash.
NEXT:
Have yourself a Well-Made red-eye
THEN:
Center the brackets together on the bar with the bolt holes as they will be mounted, and drill the holes. I started with a full size bit for a few seconds to get an accurate center point, then went to a (1/8)" bit to get all the way through. It really helps to work your way up over 3-4 bits if the bits are old and dull.
Keep track of which bracket is top and bottom as it becomes important when you mark the holes for the frame mounting
THE TRICKY PART:
Mark the bolt holes for the frame. make sure you get this right or you will need more brackets!
To accomplish this, I marked and drilled the top hole on the right side of the bike since it is easiest to access. Then I inserted a bolt in that hole to hold everything steady while I marked the next hole below it. Once the two holes were drilled, I could put a clean bolt in one and a bolt with black grease on the end in the other to mark where to drill next. Spin it around a little to get an accurate mark. Don't use too much grease!
Bolt it all together to make sure everything is kosher, then get an idea how wide you want it to be. I decided on 12" on each side to keep it a little narrow. A length of 24" and one cut.
When mounting everything for the final time, be sure to put the Loc-Tite on EVERY nut. This is a high vibration area and you do not want this bar coming off.
Once its on it should look something like this:
I plan to add folding pegs, rubber mounting for vibration isolation, and for winter maybe removable wind deflectors for my legs.
The whole thing is yet to be painted. Not sure if I should go with a black to match the body panels or a silver to match my frame and rims. What do you guys think?
I put almost 100 miles on them this evening and let me just say the added comfort is AMAZING! Gotta have it for touring.