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Discussion Starter #1 (Edited)
I really like the moto corse range of goodies including their handle bar ends however the main drawback with them in aluminium is that they are far too light...they're also available in titanium which although a bit heavier is not heavy enough to prevent the 'vibe' effect coming through the handlebars. I've been giving this a bit of thought and read a number of posts regarding a solution including merc07's recent http://www.mvagusta.net/forum/showthread.php?t=40765 My own take on it is to hollow out the moto corse bar end and add a custom made brass 'core' to give as much weight as possible. I choose brass as it's heavier than aluminium, titanium, steel, stainless steel, et all and is probably my favourite metal to work with. I'm pleased with the end result and couldn't go much heavier as I didn't want the outer part bigger (I wanted the moto corse look) and the 'stem' of the bar end at the correct diameter of 16.5mm can go no further into the brutale handlebars than 75mm (F4's may be different?) because at that point they start to narrow eventually to 10mm on the inside. Anyway here are some photos in sequence which I hope explains the procedure more fully. Cheers for now Brian (BG) Wells
 

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no kidding, i'll take a set too. pm me how much if you're willing.
nice work
Good thinking, I guess you already had the motocorse ends ?

I rekon the difference in a stainless head against the aluminium would offset the slight extra weight of the brass stem.

Mine are only 50mm in length and weigh 125g, I took the measurements from a copy of the motocorse ends. The stems were 16.8mm but with no o ring on them does that make much difference ?.

I guess if I made them 75mm they would weigh in at 150g +

Cheers
Adam
 

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Discussion Starter #6
Good thinking, I guess you already had the motocorse ends ?

I rekon the difference in a stainless head against the aluminium would offset the slight extra weight of the brass stem.

Mine are only 50mm in length and weigh 125g, I took the measurements from a copy of the motocorse ends. The stems were 16.8mm but with no o ring on them does that make much difference ?.

I guess if I made them 75mm they would weigh in at 150g +

Cheers
Adam
Trouble is though you can't make the stems 75mm long as that measurement 'includes' the rubber well nut fastener to retain them. You could though have the 'end' of the stem tapering and use a smaller diameter rubber well nut fastener in order to gain a little more weight. I'd considered this however with the rubber 'retainer' gripping on the taper deep inside the bar it 'may' want to work its way loose?. The main reason the other aftermarket bar ends are heavy is due to the outside 'visible' part being so big...if this isn't an issue you could make them as heavy as you like. Yes I went for 16.5mm diameter stems and machined for a rubber 'O' ring to help absorb the 'buzz'. The moto corse aluminium ends are really only caps or covers as I machined out as much as I could without going through the retaining bolt hole 'seat' or 9 decorative 3mm drilled holes on their face. It 'is' possible to gain a little more weight if the 'moto corse' end was made a little bigger or the end of the stem tapered as described (for the Brutale anyway...dunno for the F4). Alternatively the whole thing could be made in brass...if that's your bag?..or like 'green hands'. Cheers Brian:)
 

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so will you be selling these as a complete kit? that way we can just pay you and have you get the ends and everything.
 

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Trouble is though you can't make the stems 75mm long as that measurement 'includes' the rubber well nut fastener to retain them.
The originals on the F4 are 46mm from the edge of the head.
Mine are just 35mm and I made the head 15mm x 28.5mm - what is the Corse head measurements ?

Not so sure on green hands though !

Have you thought about the frame plugs

Cheers
Adam
 

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Discussion Starter #9
The originals on the F4 are 46mm from the edge of the head.
Mine are just 35mm and I made the head 15mm x 28.5mm - what is the Corse head measurements ?

Not so sure on green hands though !

Have you thought about the frame plugs

Cheers
Adam
Yeah I made these brass ones the same (46mm from the back of the 'head') and with the rubber retaining nut a total length from the back of the head attached it measures 64mm. I could make it about 8-9mm longer before the taper starts but that would require getting longer stainless steel bolts and the weight advantage would be???.. minimal.. and would be deeper in the bar...is it worth it? who knows. The moto corse head measures 28.3mm diameter x 15.9mm. Yeah I have made many other 'bits' and other frame plugs that moto corse don't do http://www.mvagusta.net/forum/showthread.php?t=34451
http://www.mvagusta.net/forum/showthread.php?t=34819
http://s1210.photobucket.com/albums/cc412/bgwellsuk/
http://www.mvagusta.net/forum/showthread.php?t=37009
I've also made other frame plugs and 'bits' that I'll post in due course. So I've been busy! The commercially available frame plugs that moto corse do I bought as I wanted to make other 'parts' that no one else does. Hope this helps...cheers for now Brian :)
 

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I don't have the Corse bar ends, but I would gladly pay you for the cost of the ends and the mod if it will help reduce vibrations. Let me know.
 

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I don't have the Corse bar ends, but I would gladly pay you for the cost of the ends and the mod if it will help reduce vibrations. Let me know.
Nice work on the plugs Brian, I'm guessing the normal plugs were original and you just made up the other oval type.

Thats one way to get the curve I guess - a socket and a file.
Must have taken ages to get it right...

I thought making a holding tool to put the angled frame plug in the lathe chuck and keep the face at 90 degress would be the best idea but I'm still thinking about it.....

Hyper,

I don't think either Brians modified Corse bar ends, or my stainless copies are going to be any better at keeping away the vibrations than the originals. They are 2/3 the weight of the originals.

They are just the best you can get with that type of design.

It's all about compromise. The originals are big and ugly for a reason but the aftermarket versions look good. That said I don't think they will be any worse either.

I ran mine with no bar end at all and there was no difference in that than with the original. If you run an aluminium bar end the vibrations are horrible.

Cheers
Adam
 

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Discussion Starter #13 (Edited)
Nice work on the plugs Brian, I'm guessing the normal plugs were original and you just made up the other oval type.

Thats one way to get the curve I guess - a socket and a file.
Must have taken ages to get it right...

I thought making a holding tool to put the angled frame plug in the lathe chuck and keep the face at 90 degress would be the best idea but I'm still thinking about it.....

Hyper,

I don't think either Brians modified Corse bar ends, or my stainless copies are going to be any better at keeping away the vibrations than the originals. They are 2/3 the weight of the originals.

They are just the best you can get with that type of design.

It's all about compromise. The originals are big and ugly for a reason but the aftermarket versions look good. That said I don't think they will be any worse either.

I ran mine with no bar end at all and there was no difference in that than with the original. If you run an aluminium bar end the vibrations are horrible.

Cheers
Adam
Yeah the frame other frame plugs are the moto corse ones and as I said I am only interested in making 'bits' no one else makes. You're right the file and socket technique took ages....LOTS of trial and error!...and to make it even more time consuming the hole or recess they're for tapers both ways in length and width!!....and and left and right plugs are different sizes...Bikes Eh??. As for making copies of the moto corse frame plugs... the compound curve on their faces would maybe have to be done by hand?, also their 'face' angles are different from the lower to the upper plugs.., so again a bit of a challenge unless the 'tool' you had in mind could be made adjustable?. Today I was making 'new' moto corse ends for the bar ends...a little bit bigger (20mm deep instead of the 15.9mm moto corse originals) and hollowing them out as before to gain a little more weight with a bigger end on the brass core....sucessful....but I don't know, it just doesn't look right. I'll maybe reduce them to 18mm which is just over 2mm more than the moto corse ones and get another 'look' at it. But again the weight gain over what I've already done would be minimal. Cheers Brian:)
 

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God but you do nice work. What a joy to see talent like that. Well done Amigo!

I know how much time you have in those and you need some professional help. Heh heh heh.
 

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Wow, Brian -

Really nice work. You really do have the "disease". Saw your posts of those other frame cover pieces you fabricated. Beautiful stuff.....

Regards, Ted
 
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