flangeflange

I just wondered if anyone ever had to do this -- I have some North Road bars that I'm putting on a build for my girlfriend and I purchased some brake levers for it without thinking about measuring the diameter (I had previously used them with TT style lever which mounted into the end of the bars, but they were a bit spongy feeling).

Anyway, the levers turned up and their clamp is 22.2 but the bars are 23.8. These are the levers -- https://i.ebayimg.com/00/s/MTIwMFgxNjAw/z/c4oAAOSwLqFV8tNT/$_57.JPG (I removed the plastic sheath and shifters because they're gonna be bar taped over) -- they have the standard Shimano clamp, with a ring that has two prongs with holes, small 'tug bolt' that fits between them and grabs the holes, and a bolt coming through from the main lever that pulls them towards it to affix.

Anyway, I took the ring off, put it on the bar, then plier'd the ring to close it up a bit, then I put the small bolt in, and pliered underneath it to try to straighten out the two sides of the ring (I can't describe this any better -- but if you've done this you'll know) then I, with a bit of effort, reattached the main brake and used the reattachment process to re-set the shape of the clamp essentially.

I just want to know if anyone has done this and whether it's considered safe? There just aren't a great variety of straight bar style levers for 23.8mm bars.

dsbrantjr

I would not use them myself. Bending aluminum, especially the alloys typically used for cast parts, can cause cracks which can lead to eventual (or immediate!) failure, not a desirable thing for brake components. What is your girlfriend's safety worth to you?

Here are some levers for 23.8mm bars and short-pull (canti and caliper) brakes, you did not state which you have:
Inexpensive but serviceable with a retro look - VO City Bike Brake Levers - Levers - Brakes & Parts - Components
Higher-end and very pretty IMO- Grand Cru Brake Levers, Regular Pull - Levers - Brakes & Parts - Components

The VO ones also come in long-pull for V-brakes: Grand Cru Brake Levers, Linear Pull - Levers - Brakes & Parts - Components

flangeflange

The clamp rings themselves are not made from aluminium -- in fact, I don't think any part of this brake is aluminium -- it's all steel. It's an old, fairly heavy brake/shifter combo from the mid 80s. Exage Mountain. I think the levers themselves are heavy plastic.

To be honest, I considered just adapting the levers because I actually own some of those Weinmann straight levers, and considering how incredibly flimsy they feel, I assumed it these parts aren't really bearing much of a load.

Last picture I took to show progress (saddle isn't final, needs the bars taped up and a clean/paint touch-up) -- https://puu.sh/lIYQo/17c87cdc97.JPG -- I'll take a closer picture of the brakes if you think that would demonstrate whether it looks dodgy or not.

Put it this way -- I'd ride them. I'm just a bit nervous about her on bikes, but that's not so much because of the bike.

The setup at the minute is an RX100 dual pivot on the front, so most of the braking is coming from there, and a Weinnman 720 on the back, because it's too long reach for the rear RX100.

flangeflange

Just another post -- here's what they look like up close -- https://puu.sh/lIZNe/cfd3e5a32f.JPG and https://puu.sh/lIZPY/1df8e21ef2.JPG

The fouling on the bars and brakes themselves was already there before my procedure. Whether that sways you, who knows.

I have put some serious grip into testing them over and over and don't feel any budge or reason to feel insecure. I'm more insecure about the ****ty old Weinmann on the back, which I'll probably replace.

Anyway, your perspective is appreciated. Thanks.

dsbrantjr

Ah, a picture is worth a thousand words. Many newer levers have a cast aluminum clamp which will likely crack if bent. Yours appears to be steel, with an aluminum lever body and should be OK the way you have it.

fietsbob

Look for a common 7/8" tube handlebar if you want to run a MTB Brake lever, why seek a difficulty you can avoid..

the pictured one is uber-cheap , seek out a thumb shifter and a separate brake lever.. there are some made more versatile in fit.

I cannot judge safety of the outcome.. without watching the job as performed , in person..