caintuck

On my old bike, I've got Kusuki bullmoose handlebars with a 22.4-mm OD. I want to install some bar ends for weekend touring (I know, dorky looking but...). My searches tell me that all MTB bar end clamps are 22.2 mm and all are made of aluminium. So is it possible to widen the clamps 0.2 mm without cracking them or otherwise over-stressing them? And even if it's possible, am I risking a serious accident by doing so?

Thanks as always for any input.

LWaB

Where do you get 2 mm from? You have 0.2 mm difference in diameter, so less than 0.7 mm difference in circumference.

caintuck

Thanks for pointing out my error. I got 2 mm from my total lack of attention to that decimal point. I edited my post to show that 0.2 mm is correct. So now the question is: can I widen the clamps 0.2 mm?

How embarrassing; that incorrect topic heading will live forever.

JiveTurkey

Never heard of 22.4mm. Where did you get 22.4mm for the bar? Did you measure yourself? If so, they're likely standard 22.2mm and either the measurement was off or that's an insignificant variation.

caintuck

My LBS measured it. He was surprised too. A while back I tried to install some 22.2-mm grips for the bars and they would not fit. Ended up using bar tape. Anyway, I'm not thinking of forcing the clamps to open wider; I'm thinking of somehow sanding material from the inside of the clamps. That should work, shouldn't it?

LWaB

Sanding or careful reaming should be fine.