How can I safely reshape my aluminum alloy handlebar? I'm talking just a tiny bit of bending on both sides of the bar. Can it be done without compromising structual integrity? Thanks.

I would assume that the same prohibitions on cold forming aluminum frames would preclude such an attempt.

Oops. Don't bend aluminum.

Not even a tweak?

Why??? Why tweak it, its not going to make any difference and it will snap.

Yes.....I should have known better about the properties of aluminum....
I'll trying tweaking steel handlebars instead.

There are a surprising number of "pre-tweaked" styles of bar besides the standard flats and drops. Italian company 3TTT make quite a few..

Thank you.......I'm looking for that 'custom bend'. I'll look for a used steel track bar and work on that.

I'm curious as to what you could possibly want that isn't available all ready. A vague description would be nice, but drawings and pics of the finished item would be great.

I'll post a pic of the modified bar.....soon.....

My aluminum MTB bars are getting tweaked....anyone remember the old Profile BMX bars? A similar tweak.

Aluminum has a yield strength very close to its ultimate strength. In other words, it is quite brittle, and prone to breaking. It just doesn't take bending very well at all. That's why aluminum frames are built with such large tubes. The frame cannot be permitted to bend to any degree. Those extra big aluminum tubes also provide the "stiff" aluminum ride. While steel is actually much stiffer than aluminum, it has an ultimate strength much greater than it's yield strength. So, steel tubes can be made very thin and small, allowing the entire frame to provide some flexing, thus producing the "steel" ride qualities.