Best type of drill bit for fairing mod?

[Tom G in Chester NJ]

Wondering if anyone has experience drilling through the Tupperware. I’m adding a pair of forward crashbars which require a slight (eek) modification - cutting a 1” hole on the left and right fairings.

considering a hole saw, boring bit (flat, not an auger) or a Forstner bit.

Any advice appreciated.

 

[RichKat]

A step drill bit works best on plastic, drill a ⅛ hole in the location, then enlarge with step bit, I use them all the time building signs for work

 

[Bush]

Have to ask this - why add crash bars when the built in tip over protection does basically the same job?

 

[RichKat]

Have to ask this - why add crash bars when the built in tip over protection does basically the same job?

I watched a video of a police chase, two cycle officers caught up to a suspect, and jumped off their ST's, just letting them fall, bikes rolled on their sides and then rolled back, after they just picked them up and road off, with no obvious damage

 

[Al st1100]

Have to ask this - why add crash bars when the built in tip over protection does basically the same job?

they don't save the mirrors

 

[Larry Fine]

they don't save the mirrors

What will on an 1100?

 

[Igofar]

Are you planning on chasing bad guys, and jumping off your bike and letting it fall over?
Be very careful measuring where you drill, as you'll only have once chance at it.

 

[NVDucati]

Wondering if anyone has experience drilling through the Tupperware. I’m adding a pair of forward crashbars which require a slight (eek) modification - cutting a 1” hole on the left and right fairings.

considering a hole saw, boring bit (flat, not an auger) or a Forstner bit.

Any advice appreciated.

On "plexiglass" type plastics which can shoot off a crack with a conventional drill bit ... run the drill in reverse. For a hole that big a NEW hole saw is likely the best choice. You can still run a 1/8" pilot hole to accommodate the hole saw's starter drill bit.
PS: I have a police model 1300 and those extra crash bars are a good defense plus if it ever just plain tips over, they make it easier to get it back on the wheels.

 

[SMSW]

Never use a boring bit or Forstner bit on plastic. The spade bit will grab and rip the pilot screw out of the center hole and the Forstner bit's wide chisels will also grab the plastic. Step bit (as suggested by @RichKat) or a clean sharp hole saw will both do the job. If possible, clamp a piece of wood to the back of the plastic and drill slowly, with light pressure into that. The tupperware on ST's is soft and should present no problems.

 

[Larry Fine]

I used a hole-saw when I added tweeters to my Rooster. There already was a lighter hole on the left, so I cut the right hole first, and used the slug to center the pilot bit for the second hole:

 

[Al st1100]

What will on an 1100?

training wheels

 

[Larry Fine]

training wheels

Oh, sure. Next you're gonna suggest not dropping the bike, I'll bet.

 

[pmatulew]

Steps bit are awseome on thinner materials. Will punch perfect holes even in thin sheet metal. Get you some.

 

[Al st1100]

Oh, sure. Next you're gonna suggest not dropping the bike, I'll bet.

It's not the riders fault it's the bikes fault. If it misbehaves, shoot it

 

[Sadlsor]

I would shoot a Harley 100 times, before I'd shoot my ST.
Actually, I wouldn't waste the ammo on the HD... bullets are too expensive now.
Honestly, though -- I dropped my ST a couple days after I got it, trying to do tight 180s (u-turns to some). Always some of the first things I do with new-to-me motorbikes.
I wasn't accustomed to the weight in the turn, and dropped it on the right side, so with my forward momentum in the tight turn, I rolled off the bike and it fell, continuing to rotate / spin / slide on the black plastic side protector and the muffler and rear tire... the black plastic side piece took the brunt of it all, and was barely ground through. There is the very slightest scuff on the bottom of the muffler, and you really have to look closely to even see it.
The right bar-end and mirror never touched the ground. I was / AM absolutely amazed. I fully expected to see grinding on the bar-end, and a smashed and shattered mirror cover. Nothing anyone can see, on either piece... and I have looked for it, trust me.
I've since added the rear luggage crash bars from a GoldWing, but haven't dropped it since then.
Not sure I can depend on the black side protectors to save us again, and I'm not willing to lay it down to see... much too heavy to lift it again. (Yes, I know how to pick up big bikes the right way. But the righter way is not to drop it in the first place.)

 

[Willsmotorcycle]

Wondering if anyone has experience drilling through the Tupperware. I’m adding a pair of forward crashbars which require a slight (eek) modification - cutting a 1” hole on the left and right fairings.

considering a hole saw, boring bit (flat, not an auger) or a Forstner bit.

Any advice appreciated.

When I got a replacement set the directions said use a laser beam. Set it up on tripod or similar where the bolt is with the plastics off. When you put the plastics back on the laser is right where you need to drill the hole. Be patient, triple check. Step bit sounds like a winner.

 

[Mellow]

It's just plastic, the drill bits in the 1st reply should work just fine.

 

[Mellow]

they don't save the mirrors

Yup, lots of 1100 guys are having a tough time finding mirror covers and it won't be long before 1300 guys start having the same supply issues.

 

[Al st1100]

Yup, lots of 1100 guys are having a tough time finding mirror covers and it won't be long before 1300 guys start having the same supply issues.

First time , I wire meshed the 2 pieces. 2nd time on same cover it cracked (in two) in different place. The wire mesh held!

 

[Tom G in Chester NJ]

Step drill was definitely the way to go! Thanks all for the advice. AND I got to add a tool to my arsenal.

Everything came out… well, ok.

The reason for the crash bars? To paraphrase Sir Edmund Hillary, because they were there. The original owner sold them to me with the bike.

And drilling/cutting the largest and most expensive pieces of plastic was of course terrifying, especially since I had no experience in that.

Thanks again for the support & advice!