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  1. #1
    Junior Member Sneaky Pete's Avatar
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    Is it dangerous to drill holes in handlebars?

    Yo,

    My LBS drilled a hole in my heat treated aluminum Nitto bullhorns in order to run the front brake cable through. I asked them about it and they assured me that there was no problem with doing this. However, I am paranoid about the bar snapping off where the hole was drilled and biffing in front a huge truck while traveling at a high rate of speed. Whadday'all think?

  2. #2
    Senior Member sers's Avatar
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    put down the pipe

  3. #3
    live free or die trying humancongereel's Avatar
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    i wouldn't worry about it. unless it's big enough to fit a rhinoceros through.

    i could also be dead wrong, but that's what i think.

  4. #4
    Old enough to know better Spudmeister's Avatar
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    Im curious - where did they put the hole?

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    Junior Member Sneaky Pete's Avatar
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    the hole was drilled about an inch away from the stem on the bottom side of the bar....

  6. #6
    Junior Member Sneaky Pete's Avatar
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    Quote Originally Posted by sers
    put down the pipe
    hey sers.... sukkabaggadix

  7. #7
    Iguana Subsystem dolface's Avatar
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    Quote Originally Posted by Sneaky Pete
    the hole was drilled about an inch away from the stem on the bottom side of the bar....
    should be fine then, unless you're some kind of huge monster it shouldn't be a problem

  8. #8
    live free or die trying humancongereel's Avatar
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    /\ right, i'm too damn skinny, so i didn't even take that into account.

  9. #9
    Seen your member! Slodo's Avatar
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    No worries. You're never gonna snap those handlebars. I promise.

  10. #10
    Senior Member sers's Avatar
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    Quote Originally Posted by Sneaky Pete
    hey sers.... sukkabaggadix

  11. #11
    information sponge
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    LOTS of handlebars have holes in them for cable routing. Personally I would choose a handlebar that already had all the holes I thought I needed for what I wanted to do with them. Did they ask first?
    Philosophy and feelings don't change the laws of physics

  12. #12
    i am sure that i hate you spud's Avatar
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    sounds safe to me, i'd check the condition few times a year for cracks/distress.
    putting the pi back in pirate!
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    Of Proposition 187

  13. #13
    make way for the MGL MLPROJECT's Avatar
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    Quote Originally Posted by Sneaky Pete
    hey sers.... sukkabaggadix
    http://www.eatabagofdicks.com
    NSFW (well not really)

  14. #14
    Wake Up America! helvetica's Avatar
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    put your handle bars in a vice and try to bend them. Seriously

  15. #15
    LF for the accentdeprived
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    Not to scare you, but close to the stem and on the underside is the place I personally would last drill a bar... It's subject to up-down forces, so drilling the front would probably be safer. Also, I sort of think there's a leverage thing going on, so a bit further would have been batter. I guess they know better than me.

    If you're paranoid, ask Nitto about it (do they have English email customer service?) If they say it seriously weakens the bar, voids warranty etc, you can take a copy of the email and ask the shop to replace the bar with an intact one, I guess.
    Quote Originally Posted by dutret
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    Bike on flickr and on FGG

  16. #16
    Senior Member filtersweep's Avatar
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    Was there a problem with taping the housing along the bar? What kind of brake lever required trepaning?

    An inch away from the stem is just weird. Predrilled bars are drilled there at all.

  17. #17
    In bikes I Trust 4nick8tor's Avatar
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    Look at all the holes in the handlebar that Merckx used for the hour record...

    http://www.classicrendezvous.com/Ben...erckx_main.htm

  18. #18
    Radfahrer Rincewind8's Avatar
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    Quote Originally Posted by 4nick8tor
    Look at all the holes in the handlebar that Merckx used for the hour record...

    http://www.classicrendezvous.com/Ben...erckx_main.htm
    But he used those handlebars for about one hour and no longer. And he didn't climb any hills and probably didn't rocked the bike.

    I wouldn't trust a handlebar with a hole close to the stem, especially not if it didn't come predrilled. That hole is a stress concentrator and since they probably just used a power drill, I guess the hole isn't even really smooth, with makes for some nice crack starts...

    Then again, that's just my opinion.
    TH 1.81 (133kg*62)

  19. #19
    In bikes I Trust 4nick8tor's Avatar
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    One hour of Merckx under full power is about a year of street riding of anyone on this forum.

  20. #20
    Tiocfáidh ár Lá jfmckenna's Avatar
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    It's common practice. Don't worry about it.

  21. #21
    roll'em high shants's Avatar
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    i can imagine that you'd only have problems if the hole is more than 1/2 or so the diameter of the bar. there will still be enough metal, if the hole is only small enough for cabling, to keep it from bending/breaking unless you are herculean.

  22. #22
    Skidmaster teadoggg's Avatar
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    i'd be ****ing pissed the hell off if someone drilled a goddamn hole in my bars without asking me first.

  23. #23
    Iguana Subsystem dolface's Avatar
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    Quote Originally Posted by 4nick8tor
    Look at all the holes in the handlebar that Merckx used for the hour record...

    http://www.classicrendezvous.com/Ben...erckx_main.htm
    there are serious questions about whether he used those bars at all...

  24. #24
    In bikes I Trust 4nick8tor's Avatar
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    There are also serious questions about whether Lee Harvey Oswald acted alone.

  25. #25
    Senior Member joeprim's Avatar
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    A round hole should not be a stress concentrator and should be alright. It might be wise to perodicaly look for cracks, but isn't that always true?

    Joe

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