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