Originally Posted by
Purpleorchid
Ozonation - Question for you regarding the plugs. Do you recall the sizing of the plug in relation to the diameter of the handlebar tube? My plugs have three "tiers" if you will. The first one is a smaller diameter compared to the other two (they're actually squares, so diameter doesn't quite make sense, but bear with me. A first smaller tier makes sense, because that tier is the first to be put into the handlebar. However the smallest tier is still way too big for the handlebar tube, which means the other two tiers are definitely too big.
I'm talking the smallest tier is about 2mm bigger in diameter than the hole and the other tiers are about 3mm too big. I tried using a mallet and was deforming the tiers, but there is no way those things are going into the handlebar tube.
Do you recall if your plugs were like that?
I wonder if grip shift plugs are different than regular grip plugs.
I had exactly the same situation. It makes no sense to me either. Because I had extra length, I lined up the corners of the square tiers with the grooves on the inside of the grips. I figured the portion of the grip that did not lie on the bar itself could compress against the square tiers when locked. But I had a bit of extra room to work with which you won't if your grips are shorter and can fit on completely. I know however that the tiers definitely deformed even though I had a bit more width to work with than you.
In your case, I'm not sure why Ergon had the plugs designed that way. Maybe other bike bars are a bit wider? I would think that you might have to shave down the tiers a bit.