Engineering custom Harley-Davidson handlebars is one the joys of building choppers and customizing Harleys. Certain clients want one-off applications, fabrication projects which will set their choppers apart forever.

The chopper handlebars you see in the photo below were created for a friend for whom I built a chopper from the ground up. The chopper was very unique, and it got featured in Hot Bike Magazine in 2007.

I was prototyping custom Harley handlebars at the time, and came up with this idea which, later on, served as a base for the Ultra Wicked Bars. I never repeated this custom design still unique to this day.

Custom handlebars made for a custom chopper

Due to the extra long wheel-base, and ultra low seating position, I gave these handlebars a large pull-back. At the same time, to avoid the 'tiller effect' where the rider would have to lean forward to turn the handlebars all the way to either direction -- a position which extends the arm opposite the turn far out, and makes turning a dangerous business -- I scalloped the inside segments to bring the controls closer to the rider and closer to the tank.

As usual I used DOM tubing, and to fit this application I powder coated the bars. The controls are after-market, and they fit Harley-Davidson's bars so I engineered the bars to accept standard fittings. All segments are TIG-welded, and molded to give the handlebars a smooth curvy look. All the wiring is internal.

Greg Rice

In this video, I show you how you can wire internally you new custom Harley handlebars.

I picked a pair of Deep Sickness® ape hangers with sharp points and turns. Their shape is typically thought to be very difficult to wire internally. The method I show you will greatly ease up your job, and reduce the total task time to about 20 minutes.

Please excuse the poor quality of the sound, we shot this one "ghetto-style" with a mini camera.