I need to make a one piece handlebar clamp to mount a steering damper. I can't use the one sold with the kit because hole placement for mounting the damper is in the wrong place for my bike.
I need a 7/8 half circle on the bottom of the clamp that extends the length of the clamp, approximately 4 inches. Technically the half circles need only be on the 2 ends, in about 1 3/8", but they must line up. I have a counterbore, but no boring bars 4" long. Also with my mill I can't tram the head so it would be hard to line up 2 cuts from opposite ends.
Does anyone know a good way to make a half circle on the edge of aluminum for this distance? Would I need to make the aluminum double wide and bore a full circle 1st, the cut it in half?|