The premier issue of Show Class magazine had a righteously simple and to-the-point How-to article by Zach from Heavy. We thought it would be cool to share it on here, since building one should be within about anyone's reach as long as you have access to a torch and a welder. For less than a case of beer, you can end up with a tidy addition to your bike that makes packing your outlaw freedom kit easier and of course, classier. Thanks, Zach and Show Class for sharing the feature.
So you need a sissy bar for that up-coming road trip...? This is for the regular Joe who wants freedom - backpacks and shit strapped to the bars don’t help the freedom factor, man. This sissy bar cost about 20 bucks and was done in an afternoon. The key - A JIG! Where to start? Well, we all know some cat whose got a non-descript sissybar laying around. Some of these sissy bars are older than you,so trust the time-honored shapes and bends. Most are made to fi t a 16” rear, but you can always tweak it a bit to fi t that 18” or 19” too.
Find a good welding surface and lay/ set bolts where the OG sissy bar you’re using as a template bends. We tapped holes for easy removal/re-use.
Kevin wanted his sissy bar 6’ tall - this is what inspired the whole “custom” height, and got the ball rolling on this project.
Line up the pieces in the jig to get an idea of what’s gonna happen in the end.
Kevin welded two 6’ lengths of 5/8” round stock together at the top.
You’re basically replicating the same bends as the OG sissy bar. Make sure you LINE IT UP.
Heat that shit up and make yer bends.
After makin’ yer two bends on each side, this is what you’ll end up with.
Bolt some bungs to the rear drop-outs where your sissy bar will mount. Put the sissy bar there to make sure it clears. It so, weld that shit together!
Hold the sissy bar in place and figure out where your it will mount to your fender... Mark it, drill it and attach it.
After drilling for your fender mounts attach a couple bungs... yer gonna weld your brace for the sissy bar to the bungs once you make it.
Make a nice bend in some round stock to use as the fender strap to connect the sissy bar to the fender mounts.
Put the strap in place and then weld it up.
You are DONE!