After test riding the quad, it became obvious that this quad bike was made for children and I am an adult.
One of the main issues with this is that the handlebars hit your knees when trying to turn.
To mitigate this issue, a bracket was fabricated from 5mm aluminium plate to extend the handlebars forward.
The design was kept as simple as possible – the measurement of the extension was the same measurement as the distance between the original bolt holes.
Fabrication was also kept as simple as possible. First a carboard template was tested for fit and it’s shape transferred to aluminium plate.
The main shape was rough cut with a jigsaw fitted with these blades specifically used for aluminium.
The fixing holes were then drilled and the top two fixings were tapped out to suit an M8 thread.
From there; the final shape was formed with a set of files and some good old elbow grease. To give a nice ‘brushed’ look; the edge was sanded down with some P180 grit sand paper.
The extension plate also provides a good mounting location for potential future lights.