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  1. #1
    I need more bikes!!! Mr. Shadow's Avatar
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    Cutting down handlebars...

    ...any best way to chop them to length? They are old chromed steel and have already been flipped to create bullhorns.
    "We are few now, but one day we will rule." That's what one of my fixies whispered as I walked by. I nodded in agreement, and thanked it for not waking the others.

  2. #2
    Senior Member jacobs's Avatar
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    A vice (or a friend holding the bike with the bars in the stem) and a hacksaw or pipe cutter has always worked for me.

  3. #3
    無くなった HereNT's Avatar
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    I would guess a pipe cutter, but I could be wrong...

  4. #4
    Perineal Pressurized dobber's Avatar
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    1 - Use a hose clamp as a cutting guide.
    2 - Use a nice new hacksaw blade
    3 - A nice vice is helpful for clamping them in a workable position
    4 - Make a couple practice cuts further down from the intended final cut

    I chopped my bars this past winter

    This is Africa, 1943. War spits out its violence overhead and the sandy graveyard swallows it up. Her name is King Nine, B-25, medium bomber, Twelfth Air Force. On a hot, still morning she took off from Tunisia to bomb the southern tip of Italy. An errant piece of flak tore a hole in a wing tank and, like a wounded bird, this is where she landed, not to return on this day, or any other day.

  5. #5
    BIG RING Bikeophile's Avatar
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    The pipe cutter option is definitely the cleanest way, and less chance for slipping...But I love dobber's idea of using the hose clamp as a cutting guide...probably cheaper than buying a pipe cutter.

    Have fun cutting!

  6. #6
    無くなった HereNT's Avatar
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    I'm wondering - would a shallow pan of water be useful to make sure that the cuts were exactly the same on both sides?

  7. #7
    Senior Member cabana 4 life's Avatar
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    i used a grinder with a cutting blade and eyed one longer than the other, i was going to fix it but now im used to it. dont listen to me

  8. #8
    I need more bikes!!! Mr. Shadow's Avatar
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    Thank you. I'll go buy a new hacksaw tomorrow.
    "We are few now, but one day we will rule." That's what one of my fixies whispered as I walked by. I nodded in agreement, and thanked it for not waking the others.

  9. #9
    Perineal Pressurized dobber's Avatar
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    Quote Originally Posted by HereNT
    I'm wondering - would a shallow pan of water be useful to make sure that the cuts were exactly the same on both sides?
    Once the first side is cut you can simply hold the severed portion up against the remaining section to get good matching cut. Remember to account for the miniscule amount of blade kerf.
    This is Africa, 1943. War spits out its violence overhead and the sandy graveyard swallows it up. Her name is King Nine, B-25, medium bomber, Twelfth Air Force. On a hot, still morning she took off from Tunisia to bomb the southern tip of Italy. An errant piece of flak tore a hole in a wing tank and, like a wounded bird, this is where she landed, not to return on this day, or any other day.

  10. #10
    Senior Member jamey's Avatar
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    i just eyeballed the bars and put electrical tape on the bars so it looked even and so i had a straight line to guide my cutting and i hacked at it..

  11. #11
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    How do you plug them once they are cut?

  12. #12
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    I'm going to second the hose clamp saw guide suggestion. Hose clamps are only like $.79 or something, and if you cut carefully, you can still use the hose clamp after on your kitchen sink or hose or something.
    Use plenty of oil when cutting; it makes things much smoother and easier. I used 3in1 oil, real cutting oil would work, as would motor oil, and maybe even chain lube!

  13. #13
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    Quote Originally Posted by skanking biker
    How do you plug them once they are cut?
    Uhh- Handlebar end plugs?

  14. #14
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    My sarcasm yet again goes unappreciated

  15. #15
    Major Major somebodies's Avatar
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    i used tape and a hacksaw. a bit rough, but very functional
    he's getting rather old but he's a good mouse

  16. #16
    I need more bikes!!! Mr. Shadow's Avatar
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    Quote Originally Posted by BostonFixed
    Uhh- Handlebar end plugs?
    I have the original bar plugs. I am running into a snag though.
    I was hoping to use a time trial type brake lever, but the tubing
    is just a bit too small in diameter for it to seat into the bar end.
    "We are few now, but one day we will rule." That's what one of my fixies whispered as I walked by. I nodded in agreement, and thanked it for not waking the others.

  17. #17
    Senior Member gmcaptain's Avatar
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    i used a friend's rotary grinder. Worked great. And I got the added bonus of lots of sparks.

  18. #18
    Beausage is Beautiful Fugazi Dave's Avatar
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    A couple notes regarding pipe cutters. If you get one, get a decent one. I have one that I used to cut a steerer tube and handlebars and that's about as far as it got before massive chunks came out of the blade. Also, be light-handed and careful using one to cut aluminum bars - it is a lot easier than you think to ovalise the end that you just cut. Finally, if you do ovalize the end of your bars, fix it before you jam a bar-end lever in there or you will NEVER get it out again without about 90 min of work, some spilt blood, and a lot of swearing.

  19. #19
    Senior Member gmcaptain's Avatar
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    Quote Originally Posted by Fugazi Dave
    Finally, if you do ovalize the end of your bars, fix it before you jam a bar-end lever in there or you will NEVER get it out again without about 90 min of work, some spilt blood, and a lot of swearing.
    I gave up. Bar-end levers weren't intended to be crammed into the curving section of chopped bars. Keep in mind that what you come up with might end up being permanent. And in my case that includes a stem as part of the permanent configuration.

  20. #20
    mike.pretzel thecosmicmuffin's Avatar
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    Quote Originally Posted by Mr. Shadow
    Thank you. I'll go buy a new hacksaw tomorrow.
    wouldnt a new hacksaw cost about as much as a new set of cheap e-bay bullhorns?
    Shake Zula the Mic Rula

  21. #21
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    For machining aluminum, the best cutting agent and lubricant is kerosene.

  22. #22
    cripple gally99's Avatar
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    1. get a pipe cutter at a flea market for five bucks...
    2. cut your bars...
    3. throw away the pipe cutter cuz it's now toast...

  23. #23
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    no need for a vice, I just held the bar against the ground and went at it with a hack saw, then filed it a little. The saw went through the bar real easy.

  24. #24
    Direct Hit Not Required BlastRadius's Avatar
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    I used electrical tape and a jigsaw.

  25. #25
    Senior Member etchr's Avatar
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    Quote Originally Posted by Fugazi Dave
    A couple notes regarding pipe cutters. If you get one, get a decent one....
    I have found that a pipe cutter works superbly and is super easy (a hacksaw?!? ugh!). just adjust the tension a little at a time (as per package instructions) and you should be able to get a nice clean cut and still be able to use it again and again. I cut my steerer tube and my bars and it still works/looks fine... just make sure you get a decent/name brand one. they are only about 4 to 8 bucks.
    Last edited by etchr; 05-18-05 at 10:54 AM.
    love delights to give.

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