Windshield Support Bar(s)

[southkogs]

Anyone ever cut their own windshield support bars to fit? If so, how do you properly crimp them?

Or alternatively, does anyone happen to have experience coordinating part numbers and sizes with Taylor Made?

------- BACK STORY HERE ---------
The port bar on my Bayliner went kaput about a week and a half ago. I happened to have an 11" bar in the garage, so I put it in there and realized it was too long. The starboard side is definitely shorter. I've looked all over the place, but I really can't find a support bar that looks like it has the same base as mine that is shorter than 11".

I called Taylor Made direct, and if I have the part numbers they can send me out a new set of bars. Don't know the price without the part numbers. They can also cut the lengths custom if I measure the shafts (9.5" & 5.75") ... $100 for the bars, $25 for processing the custom order & shipping costs. :faint2:

Contacted Bayliner about getting part numbers, and they want me to deal with a dealer. Closest dealer is over an hour away, and they only have part numbers back to 2003 (mine's an '02), and they really don't want to deal with me because they don't seem to have the part in stock and feel like I'm gonna' just buy online anyway (and I don't blame 'em). So, I'm having trouble turning up a confirmed part number. I did find a parts catalog online, but Taylor Made can't confirm the numbers that I got from that catalog and I'm starting to get a little frustrated with that process.

If I can cut and crimp the set I've got on hand, I'll give that a whirl before I spend $150 on $30 support bars.

 

[Bob_VT]

The crimping brings a few things in my mind...........

Interstate battery shops have a tool for crimping the ends on heavy cables ................

Hydraulic shops can crimp things too................

I would think that bimini hardware in the store would make the ends to .............. there are ends that either insert or cover the tube.

OR

if we lived closer I would cut one on a friends lathe!

 

[Scott Danforth]

its a roll-crimp, like bimini top hardware

I would stake it around the end with a block of wood and a center punch. its what I do with my bimini hardware

a tubing cutter with a custom wheel (not a cutting wheel) also works. however you need a lathe to make it.

 

[southkogs]

Okay - I gotta' do a bit of reading and see if I've got the tools (or skill) to pull it off. I've got a temporary, slightly too tall, bar on there right now.

Bayliner did deflect me to the dealer level, but they've actually made an attempt to get hold of me a (I missed the call) to check up on if I got situated.

 

[southkogs]

UPDATE: I got another contact from Bayliner, and got the actual part numbers. And a "thank you" to Bayliner - they stayed on this relatively simple thing and contacted me. I didn't have to chase them down.

Turns out the windshield supports are not Taylor Made, they were an in-house build by Bayliner. I can order from a dealer and get new ones.