With the band saw, I cut the basic 2 part clips, levers, and lever mounts out of 3/4" solid brass bar, and rounded them with the belt sander and the air grinder. The bottom section of the handlebar clips were tapped 1/4"-20, and an 1/8" aluminum plate sandwiched between the two halves.
The 1 5/8" holes for the forks were cut with a bi-metal hole saw fairly easily, but for some reason, I was having a hard time cutting the sideways 1" holes for the handlebars, and ended up letting a machine shop do it, as well as bore the 1" holes in the lever mounts to mount them at the end of the handlebars.
The reverse levers will be rounded with the hand held air grinder and polished, then fitted in the handlebar mounting brackets after these are drilled and shaped.
I will have to figure out a way to move the brake fluid reservoir and connect it to the lever.
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