Originally Posted by
Bikerider007
This is probably what I would do.
I considered doing barcons on mine but I it came with the matching Deore group so I didnt. I wouldn't cut the boss off. A drill, small block of steel or aluminum and a cutting wheel to cut and shape. It would have to overhang (top and bottom) on the ends with a lip (raise center) as it is a single bolt application or it would spin or move from pressure. A hole on top and the sides and good to go. Probably some trial and error but an easy solution and made by you.
If you get the parts and sell bike, the boss is usable.
Yep.
I was thinking the simplest DIY way to do it would be a block of ~3/8" thick aluminum. Drill a hole in the center the same diameter as the width of the square boss. File out the corners to square by hand. Drill stepped holes for the housing stops and cable. Round off the exterior corners as desired. At that point it could be screwed to the boss with a washer and won't spin if well enough made. The underside could be rounded to fit the down tube, or simply use a leather washer.
That should be doable with a hand drill and a vise. A drill press would help of course.
Aluminum is strong, light and easy to work. Brass is pretty easy to work too. I don't think I'd try it in steel without a drill press and a milling machine.
Another idea would be to simply use the original friction shifters. They might travel enough for 9 spd. You could get wacky and use a cable travel multiplier to get a bit more travel for 10 or 11 too I suppose. Then again indexing is pretty nice to have, especially with bags.