Am mounting a new aluminum MTB handlebar and am considering using a Dremel tool with a cut off wheel to make the cut rather than a hacksaw. Any thoughts on the sanity of doing so?

Thanks!

It will probably give you a messier cut then if you did it with a hacksaw (and guide). Your bars, your choice in how you cut them

And make sure that you don't cut too short, you can always cut more later, but can't add back on.

True that Thanks!

Just use a tube cutter, like the one pictured. I used this one to cut off a few inches on my mtn bike handlebars; totally clean cut, perfectly square, and easy to measure. Much better than hacking it off. Available at any hardware store.

You can also use a hose clamp for a saw guide.
Make sure you leave enough room for grips, shifter/brake etc.
I had trimmed a bar (about 1" on each end) when I had thumb friction shifters. When I upgraded to ST-EF65's, I was about 3/4" short to fit my Ergon grips.

+1 on the tube cutter--cleaner cut vs a hacksaw.

Tube cutters work well (a little oil on the wheel and cut area will make the job easier) although they will sometimes leave burrs on the inner and outer surfaces, since they push metal aside to make the cut, but that is easily cleaned up with a little file work.

I used the bike shop's hacksaw cutting guide and the cut came our square.. which is why the saw guide exists..

It is used mostly for threadless steering tubes , but adjusts for smaller as well..





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Thanks again all! The tube cutter looks to be the tool for the job. I'll stop by Harbor Freight and pick one up - yes, I know their tool quality isn't the best but I'm only going to do this once or twice and at $6.00 if it works a couple of times I'll be happy.

I always use my pipe cutter.

My thoughts too. I slide the shifters, brake levers, grips and anything else to be mounted onto the handlebars to test fit how much space is available before cutting. If the handlebars have a rise to them, I'm always surprised at how little space is available.

Done! Bought the $5 tubing cutter, used some 3 in 1 oil. Nice flat cut . Used the dremmel sanding drum to remove the flair from the ends.

Thanks fur the suggestions!