Join Date: Sep 2018
Location: Brooklyn, NY
Thanked 10 Times in 10 Posts
Total cost about $30 plus tax.
- The Hillman Group 3/8 in. Stainless Steel Flat Washer (15-Pack)
- Rust-Oleum Automotive 15 oz. Black Truck Bed Coating Spray
- Everbilt 3/8 in. -16 tpi x 1 in. Stainless Steel Hex Bolt
- Everbilt 1 in. x 36 in. Plain Steel Flat Bar with 1/4 in. Thick
- The Hillman Group 3/8 - 16 in. Stainless Steel Nylon Insert Stop Nut (8-Pack)
a) The bottom connection point of Cobra Highway bars is tapered, where the part touching bike frame is 1 inch, and part welded to the HB tube is 1.5 inch. It will be easier to work with 1x36x0.25 inch steel flat bar, and that should be plenty strong over the 3-4 inches of length of the strap/extension. Probably aesthetically more pleasant as well.Wish me luck
b) It is easier to source (at least for me in Brooklyn, NY, USA) bolts with inch (Imperial) measurements rather than metric. If I were anywhere else but America, it would probably be the opposite. If you are a purist, and just about to have a heart attach at the thought of putting Imperial parts/hardware on a metric bike, I'm terribly sorry (not really).
c) I will be using a jig saw with Bosh metal blades left over from other projects, rounding corners first by cutting excess (if I can with a jig saw) and then by filing/grinding with a combination of hand-file/grinding wheal adapter for a hand-drill.
d) Pilot holes will be made with drill-bits and brought to size (approximately 11-12 mm inner diameter to accommodate 3/8 bolts)
e) I'll use the same bolts for both the main attachment hole and secondary hole (prevents rotation) - it is easier and cheaper to source same size fasteners in stainless steel.
f) Sand and paint, 3 coats of black paint (maybe more, depends on how the paint comes out).