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Old 01-23-2010, 10:35 AM   #1
Chadx OP
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Highway Dirt Bike (HDB) top clamp and handguards

I see a lot of threads about handguards and top clamps which often touch on the products from Highway Dirt Bikes (HDB), but no dedicated thread, so here we go.

In September, 2009, after looking around at all the options available, I decided on the HDB top clamp and handguards for my 2008 WR250R dual sport. Needing a place to mount two powerlet outlets, and not wanting to add extraneous brackets, I started looking into integrating the powerlets into a handlebar top clamp. The original version of the HDB top clamp has 4 small switch holes in the upper portion. I was curious if these could be drilled out to accommodate the 18mm hole needed to mount a powerlet so I contacted Paul, at Highway Dirt Bikes, to get the ball rolling.

Here is a pic of the original top clamp that got me thinking:



After a bit of discussion on clearances and research on the various powerlets available, Paul worked up the following, replacing the four small switch holes with two 18mm holes.





I decided to go for it, so completed an order to include the top clamp, lower clamps with some rise, hand guards, Protaper Evo bars (which he tapped for me), and some of the flip out mirrors.

Then I received an email from Paul with a new idea he had worked up and, suddenly, all was right with the world.

In this image of the new design, you can see he left the top portion of the top clamp as it was in the original design but added material to create a lower portion in which the two 18mm powerlet holes could be drilled:





Paul ordered the needed material to do a run of clamps. Since I was moving to fat bars, I needed a 100mm x 40mm bolt pattern. Stock bars, or any 7/8 bars, would have used a 100mm x 33mm bolt pattern on this bike.

After a couple weeks, the first run was complete and I was pleased to receive this image of the new top clamp design with a low-profile powerlet mounted.


Chadx screwed with this post 04-27-2011 at 08:12 PM
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Old 03-11-2010, 02:11 PM   #2
DiscoDino
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Just received my custom top clamp from Paul and some other goodies...will install this weekend and post pics...

Is there anyone close to Paul at Highwaydirtbike (Niwot, Colorado, 80503) who has a 2008+ R1200GS interested in these guards & who'd like to offer his/her bike for a test fit? I just bought a 2009 R1200GS and thought there would be a market for them out there?

Thanks!
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Old 12-23-2010, 06:24 PM   #3
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Quote:
Originally Posted by fire_strom View Post
So unless you get the "ultimate" version they're about as bendy as any other brand?
For what it's worth, I have the ultimate and I've hucked my F800GS down a few times without so much as a budge of the guards.
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Old 12-23-2010, 07:51 PM   #4
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Quote:
Originally Posted by Pyranha7 View Post
For what it's worth, I have the ultimate and I've hucked my F800GS down a few times without so much as a budge of the guards.
What size is the Clamp on your GS?
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Old 12-24-2010, 04:54 PM   #5
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Quote:
Originally Posted by YamWOW! View Post
What size is the Clamp on your GS?
I'm sorry, but I don't know off hand. I live near Niwot, so I had the advantage of picking up my guards from Paul directly. He set me up with what I needed.
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Old 12-24-2010, 05:18 PM   #6
One Less Harley
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HDB guards on a DRZ400S. I had to move the speedo more to the center and up with spacers and relocating the mounting holes. Nice setup.





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Old 01-13-2011, 11:02 PM   #7
TEZZA
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Hand Guard Mirrors

Nice hand guards , where did you get the mirrors from ???
Tezza

[
QUOTE=One Less Harley;14775944]HDB guards on a DRZ400S. I had to move the speedo more to the center and up with spacers and relocating the mounting holes. Nice setup.





[/QUOTE]
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Old 01-14-2011, 03:25 AM   #8
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Nice hand guards , where did you get the mirrors from ???
Tezza
The mirrors are HDB and are options for the HDB handguards. Works nice. I have them on 2 bikes now.
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Old 01-26-2011, 08:24 AM   #9
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where are you guys sourcing the switches (push button) and led's for the top clamp?

has anyone used the mounting holes for the "led dash" to put led's in? I'll only need to use a couple of switches, so no need to add the full dash - noticed those holes and they are threaded so figured that might be a good place to put them
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Old 01-26-2011, 08:52 AM   #10
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Where did you get the turn signals to put in there? Are they Zegas?
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Old 01-30-2011, 10:03 AM   #11
Chadx OP
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Quote:
Originally Posted by fire_strom View Post
Where did you get the turn signals to put in there? Are they Zegas?
Scott
The ones in the above image look like an aftermarket install, but note that Paul does, or plans to, sell hand shields with the turn signals built in.
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Old 01-30-2011, 09:36 PM   #12
gofast1320
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Hdb

These are awesome and Paul is a super guy to do business with. Got a set a couple of months ago for my F800GS and love'em. Fit perfect, look great and yeah they work. Bike took a dirt nap on the shoulder of a gravel road and I still got my OEM levers with no damage.
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Old 12-24-2010, 06:43 PM   #13
YamWOW!
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Quote:
Originally Posted by Pyranha7 View Post
I'm sorry, but I don't know off hand. I live near Niwot, so I had the advantage of picking up my guards from Paul directly. He set me up with what I needed.
It should be stamped on top of the clamp.
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Old 12-27-2010, 05:59 PM   #14
Pyranha7
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Quote:
Originally Posted by YamWOW! View Post
It should be stamped on top of the clamp.
The clamp has 98x38 / 40mm
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South Park's 12th episode of their 13th season is proof that there is still some truth in television.
http://www.southparkstudios.com/full...e12-the-f-word
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Old 12-27-2010, 06:42 PM   #15
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Quote:
Originally Posted by Pyranha7 View Post
The clamp has 98x38 / 40mm
Thanks!
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