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  1. #1
    Senior Member daveed's Avatar
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    I'm hacksawing handlebars

    Just a quick question before I begin trimming my handlebars with a hacksaw: Do I need to be aware of any difference when sawing through alloy versus steel?
    Thanks.

  2. #2
    Senior Member joeprim's Avatar
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    Just curious - why? I've cut both steel and alum alloy. The Alum is softer or are you talking CrMo - it might be a little harder than a milder steel but I wouldn't think much different.

    Joe

  3. #3
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    Alloy is easier to saw. Make sure you file these sharp ends when done before mounting grips or bar ends.

  4. #4
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    You might want to try a tube cutter used to cut copper water supply lines. It worked great on the alloy handlebars for the hybrid and left a really nice looking, straight edge.

  5. #5
    Senior Member Old Hammer Boy's Avatar
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    Quote Originally Posted by Ranman
    You might want to try a tube cutter used to cut copper water supply lines. It worked great on the alloy handlebars for the hybrid and left a really nice looking, straight edge.
    +1 on this suggestion. Much easier and more accurate. Also, no burr.

  6. #6
    Senior Member daveed's Avatar
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    Thanks to everyone for the quick, helpful replies. I don't have a tube cutter but my hardware store might do this for me.

    Joeprim: I ride a fixie and I like the way shortened flat bars look with grips. Plus, I run a brake lever that doesn't easily clamp to mountain bars unless mounted near the stem; hence, I want to move my hand closer to the lever. What more, the bars cost me just $10, NOS. Call me crazy and vain!

    Dave

  7. #7
    Senior Member joeprim's Avatar
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    Hey you like what you like who else cares. When you file the handle bar ends after you cut them off put chalk on the file it makes getting the file clean easier.

    Joe

  8. #8
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    Tubing cutters work well on straight wall tubes like water pipes and fork steerers. If the handlebars are at all tapered at the point they are being shortened, the cutter will "walk" as it is turned and won't make a straight cut. A hacksaw, used properly, is a better bet for this.

  9. #9
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    One thing I have found helpful in cutting tubing "straighter" with a hacksaw id getting a hose clap of the approiate size, clamp it on the tubing and then cut next to it using it as a guide. Cut several frametubes for a recumbent I am building this way over the weekend. Cut the time filing ends square to almost nothing. YMMV

  10. #10
    Senior Member daveed's Avatar
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    Quote Originally Posted by imabeliever1
    One thing I have found helpful in cutting tubing "straighter" with a hacksaw id getting a hose clap of the approiate size, clamp it on the tubing and then cut next to it using it as a guide. Cut several frametubes for a recumbent I am building this way over the weekend. Cut the time filing ends square to almost nothing. YMMV
    Brilliant idea. Now you tell me. The filing actually wasn't that bad. As soon as the bar end looked close to even I stuck in the plug and pulled the grip as far over as it would decently go. The issue was cutting to measurement: 40 mm. Now that I didn't achieve. Hey, first time out ... thanks again.

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