Originally Posted by wret
The 7/8 OD bar probably has in ID close to 1/2 inch. Compared to the 1 inch ID pipe, it would only have about 1/4 the volume. Huge difference.
That would mean handlebars are 1/4" wall thickness? Sorry. Your calculations are way off, sir.
1/8" difference will never be enough to impact the way your little engine will perform. I promise you. Use the 7/8" handlebar material. It is probably already chrome plated so your exhaust system will look good and work just fine.