The standard Empi nerf bars sold by most sources are completely wrong for the typical speedster replica. Their mounting bars are too thick, too wide, and have their holes in the wrong places. Even if you could install them, the lower curved sections sit dangerously low to the ground.
Naturally I discovered this after buying four of them. Hence my earlier rant on how nothing just “bolts right on.” The alternative was to have someone make me a set. But that turned out to be too expensive. So, to save my initial investment, I set about making the Empis work.
1) Cut off the chrome mounting bars, keep the four curved chrome pieces.
2) Buy the two front, and two rear, mounting bars used for the standard fiberglass bumpers. About $9 each from Vintage Speedsters.
3) Make a paper pattern of the front and rear mounting bars, and one for the curved chrome piece.
4) Put the bars’ patterns in place and adjust the curved chrome piece’s pattern to suit. You’ll probably have to shorten one or both ends of the curved piece. Play with things to get a custom fit.
5) Mark the front and rear bar patterns to match the curved piece. Use the patterns as guides for cutting the metal mounting bars.
6) Weld the bars to the curved chrome pieces. This cost me $30. If needed, use a tube cutter to shorten the curved chrome pieces.
7) Paint, powder coat, or chrome.
8) Don’t forget to fasten the rear ground wire to one of the mounting bolts when installing your new custom nerf bars.
