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I was interested in a highway bar floorboard due to its price of $50 plus shipping. Its only for 1 inch highway bars but it could be borded out to 1 1/4 inch ? (which is the size of my tube) Since it is so much cheaper than anything made for 1 1/4 inch do you think it would be worth it? What downsides do you see?

The floorboard can be seen at http://www.jcwhitney.com/autoparts/Item ... up_listing

FYI, I have access to a varialbe speed, oil cooled, vertical drill press.

Thanks Dan

It's kinda hard to see if there is enough metal to increase the mounting hole that much. If you got into the holes for the mounting bolts it might weaken the part too much.

From the look of the picture, I would say there is enough metal to drill the mount out to 1 1/4 and leave enough beef to be solid. If you have a way to do it. It might be easier to have a machine shop do it in a milling machine or large drill press. Doing it by hand could easily mess up the mount. A 1 1/4 bit on a hand drill powerful enough to turn it puts out considerable torque and will be hard to hang onto. You will also likely chip the chrome around the hole leading to rust issues. Not a function problem, but cosmetically less than great. It should work though from the look of it.