How to Make Custom Motorcycle Handlebars: A Step-by-Step Guide

Ever wondered how to make motorcycle handlebars that perfectly suit your riding style? Crafting your own handlebars can be a rewarding project, giving you the freedom to customize your bike’s look and feel. Whether you’re aiming for a classic cruiser vibe or a sleek, modern design, building your own handlebars lets you achieve that personal touch.

Key Takeaways

  • Crafting your own motorcycle handlebars offers customization to perfectly suit your riding style and aesthetic preferences.
  • Understanding the various types of handlebars, such as Ape Hangers, Drag Bars, and Clubman, helps in selecting the right design for your motorcycle.
  • Selecting the appropriate materials, like steel, aluminum, or titanium, ensures durability and performance of the handlebars.
  • Ergonomic factors and legal regulations should guide the design process to ensure comfort and compliance.
  • The fabrication process involves precise steps including measuring, cutting, bending, welding, and finishing the handlebars.

Understanding Motorcycle Handlebars

Types of Motorcycle Handlebars

Motorcycle handlebars come in various designs, each catering to different riding styles and preferences. Ape Hangers rise high above the mounting point, perfect for choppers and distinguished by hands positioned well above the shoulders. Drag Bars offer a streamlined look, placed low for a more aggressive riding posture. Clubman Handlebars angle downward, providing a sporty appearance suited for café racers. T-Bars combine the rise of ape hangers with the straight grip of drag bars, offering versatility in both form and function. Z-Bars display sharp angles and unique looks for custom builds. Beach Bars are wide and gently curved, ideal for a relaxed, cruiser feel.

Materials Used in Making Handlebars

Motorcycle handlebars use various materials to ensure durability and performance. Steel, known for its strength and affordability, is common in many handlebars. Chromoly, a steel alloy, offers superior strength-to-weight ratios and is often found in high-performance bars. Aluminum provides lightweight options without compromising durability making it suitable for sport and racing motorcycles. Titanium, while more costly, offers ultimate strength and corrosion resistance for premium builds.

Ape HangersHigh-rise, hands above shoulders, ideal for choppers
Drag BarsLow, aggressive posture, streamlined look
ClubmanDownward angle, sporty appearance, suited for café racers
T-BarsCombines rise and straight grip, versatile
Z-BarsSharp angles, unique look, custom builds
Beach BarsWide, gently curved, relaxed cruiser feel
SteelStrong, affordable
ChromolySuperior strength-to-weight ratio, high-performance
AluminumLightweight, durable, suited for sport and racing
TitaniumUltimate strength, corrosion resistance, premium builds

Understanding these types and materials helps ensure you choose the right handlebars for your motorcycle, enhancing both aesthetics and performance.

Designing Your Handlebars

Planning the Design

Start with a clear vision for your custom motorcycle handlebars. Sketch different shapes, considering your bike’s style and functionality needs. Identify the diameter, width, and height suitable for your ride. Analyze existing handlebar designs (e.g., Ape Hangers or Drag Bars) to gather inspiration and understand common dimensions. Ensure your design complies with local regulations—handlebar height and width vary by jurisdiction. Check these regulations before finalizing your plans to avoid legal issues.

Ergonomics and Comfort Considerations

Prioritize ergonomic factors. Positioning affects riding comfort and control. Measure your arm length and seating position. Test handlebar mock-ups with different sweeps and pullbacks to find the most natural grip. Ensure the design reduces strain on your wrists, shoulders, and back during extended rides. Integrate control access, like throttle and brake levers, into your ergonomic planning. Proper spacing of these controls on the handlebars ensures quick and effortless operation, enhancing overall safety.

Fabrication Process

Tools and Equipment Needed

To fabricate motorcycle handlebars, ensure you have specific tools and equipment. Essential tools include a tubing bender and a welding machine. Tubing benders facilitate bending metal pipes to the desired shape. Welding machines join metal pieces securely. Other tools needed are a pipe cutter, for cutting metal to size, and a measuring tape, for accurate dimensions. Metal files smooth out rough edges. Safety equipment, such as gloves and welding masks, is critical to protect yourself during fabrication.

Steps in Making Motorcycle Handlebars

Creating motorcycle handlebars involves precise steps. Start by selecting the appropriate material, typically steel or aluminum. Both materials are durable, but steel is heavier compared to aluminum. Measure and cut the metal tubing to the required length using a pipe cutter. Accurate measurements are essential to achieve the desired handlebar dimensions.

Next, use a tubing bender on the metal until the desired angles for the handlebar are achieved. Follow the design plan carefully to ensure ergonomic comfort and compliance with local regulations. After bending, weld the handlebar sections together, ensuring that all joints are strong and secure. Perform an initial quality check, inspecting the welds and bends for any imperfections.

Once welded, use metal files to smooth out rough edges and surfaces. This step ensures that there are no sharp points that could cause injury or discomfort while riding. Then proceed to test fit the handlebar on the motorcycle. Testing ensures that the handlebars meet ergonomic and functional requirements.

Finally, finish the handlebars by cleaning and applying any desired coatings. Painting or powder coating provides protection against rust and gives a polished look to your custom handlebars.

Finishing and Installation

Finishing Touches

Smooth the surface of the handlebars using sandpaper or a file to remove any rough edges or welds, ensuring a comfortable grip. Apply a primer to the bare metal to prevent rust, then follow up with a durable paint or powder coating to enhance protection and aesthetics. Choose high-quality coatings specifically designed for metal surfaces to ensure long-lasting results. Allow adequate drying time between coats to achieve a smooth, even finish.

Installing Handlebars on a Motorcycle

Begin by positioning the handlebars on the motorcycle’s triple tree or handlebar mounts. Ensure the bars align with your preferred riding position. Secure the handlebars using the appropriate bolts and a torque wrench, tightening them to the manufacturer’s specified torque to prevent slippage. Attach the throttle, brake, and clutch controls, ensuring they are correctly aligned and functioning smoothly. Adjust the mirrors, brake levers, and clutch levers to your preferred positions.

Run the cables and wiring along the handlebars, ensuring they are secure and not obstructing any movements. Tie the cables using zip ties or cable clamps for a tidy appearance. Inspect the installation for any loose components or misaligned parts. Test the motorcycle’s control functions to ensure everything operates correctly before taking it out for a ride.


Crafting your own motorcycle handlebars is a rewarding endeavor that allows you to tailor your ride to your exact specifications. By carefully considering design, materials, and ergonomics, you can create handlebars that enhance both comfort and style. The fabrication process requires attention to detail and precision, ensuring each step from cutting to welding is executed flawlessly. Once you’ve completed the finishing touches and installed the handlebars, you’ll have a unique, custom component that not only looks great but also performs reliably. Enjoy the satisfaction of a job well done and the superior ride quality that comes with custom handlebars.

Frequently Asked Questions

What are custom motorcycle handlebars?

Custom motorcycle handlebars are handlebars specifically designed and built to meet the rider’s personal preferences, including style, material, and ergonomic comfort.

What types of handlebars can I choose from?

You can choose from various types like Ape Hangers, Drag Bars, T-Bars, Z-Bars, and Clip-Ons, each offering different style and riding comfort.

What materials are commonly used for custom handlebars?

Steel and aluminum are the most common materials used for custom handlebars due to their durability and versatility.

Why is ergonomic planning important for custom handlebars?

Ergonomic planning ensures that the handlebars provide maximum comfort and reduce strain on the rider, which is crucial for long-distance riding.

Do custom handlebars need to comply with any regulations?

Yes, custom handlebars must comply with local and federal regulations, including height and width restrictions, to ensure safety and legality.

What is involved in the fabrication process of custom handlebars?

The fabrication process includes selecting materials, cutting, bending, welding, testing, and finishing to create handlebars that meet specific requirements.

How do you finish custom motorcycle handlebars?

The finishing process involves smoothing rough edges, applying protective and aesthetic coatings, and ensuring a polished look.

How do you install custom handlebars on a motorcycle?

The installation process involves positioning the handlebars, securely fastening them, attaching controls, running cables properly, and testing for proper functionality before riding.

Why is testing custom handlebars important?

Testing ensures that the handlebars are secure, functional, and provide the necessary comfort and control before taking the motorcycle on the road.