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2007 Kawasaki Vulcan 500

Highway Bar & Pegs

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I have been passionate about motorcycles since a young age and received my motorcycle endorsement just months after attaining my driver’s license. I purchased my first 125cc bike at 16 years old before upgrading to a 500cc cruiser at 18. This Kawasaki cruiser did not have an available commercial solution for adding a highway bar and set of pegs to it. This was the summer of 2020 and my machining class for university was online due to Covid-19. I had sought out a local machine shop and was apprenticing there.  Thus, when I was looking to upgrade the motorcycle with this dual-purpose component, I realized I could design a system and then manufacture it at said machine shop. That is exactly what I did. I started with measurements on the motorcycle itself and used cardboard with masking tape to flesh out the spatial requirements. I then did hand calculations based on the static loading and an theoretical worst-case impulse load that the highway bar would see if the motorcycle was laid down. I then used SolidWorks to model all the components and ensure proper functionality. I used scrap blocks of 6061 aluminum to hand mill the pegs. For the highway bar, I used 1” steel tube from McMaster which I cut, MIG welded, and painted. Stainless steel U-bolts were passed around the bikes tube frame and used to attach the bar. The highway pegs have functionally worked for my rides across the state of Florida and the highway bar has saved the body of my bike from two crashes at low speed.

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