For a long time, the stock GasGas 7/8" bars and Hebo replacement 7/8" bars had the thickest walls in the industry. It's part of what made them so dadgum strong. However, it made installing the Barkkbuster's bar end inserts a pain.
I wasted a bunch of time setting up bikes for us and for customers, at first.
After trying several unsuccessful avenues, I finally bought a special "stepped" 1/2" shanked drill bit ($27. I think it is a 35/64" bit, but will have to check.) to hawg out the bar ends. No more problems, except when someone didn't put it back where it belonged and I had to purchase another.
For the last few years, the stock bars will almost always accept the inserts with no modification. (Anyone need a good used drill bit for a discount?)
