Hey Marty, Dalroo and I are getting Kevin to powdercoat our bars as well, and I was wondering, would you suggest enlarging any holes before powder or does it not matter?
It does not matter, as the holes to be enlarged are on the bike not the bars. The pin that holds the passenger foot peg on is smaller
in diameter than the bolt that comes with the MCE bars. I needed to enlarge the hole in the passenger foot peg itself and the two holes
on the bracket that holds the peg. I measured the large part of the MCE supplied bolt above the threads and it measured .243" so I just drilled the holes to .250" because I didn't have any letter drills at hand.
So what would I do different?
I had Kevin mask the little boss on the end of the upper mount. I shouldn't have bothered, it's not that
tight of a fit. I should have test mounted the bars before giving them to Kevin to coat, then I would have seen that. When I saw how the un-coated part was going to be visible I just "painted" it black with a Sharpie marking pen. So don't bother to have Kevin mask anything. Second thing to consider is that when you take the passenger foot peg off, there is a steel ball and spring that may go flying off somewhere, so watch for that.