Fitting bar end shifters into bars...problem...
 

My wife's bike is being built up with Civia Bryant 26.0 handlebars. We got Shimano 10-speed bar end shifters to put on the ends. But it doesn't fit! Did we buy something wrong? Is there a way to bore out the bar ends by a millimeter?

Thanks!

yes, have any Machine shops in your town?[ that is in trying to do it properly.]
they can clamp the bar upright in a drill press with an appropriate sized drill bit.

Your bar was probably made with a thicker tube wall for safety.
Nitto Mustache bars take bar ends and come in 25.4 and 26" OD centers
26 is commonly a Road Bar Is this a road bar too?, should go in as is .

Nitto Albatross bar, in Chromoly is using a stronger material
so the 22.2 OD is thin wall tubing. 25.4 .. + shim to the larger stem clamp.

you might get away with grinding down the end of the mounting bolt, to fit, inside,
or there is an alternate pod that goes around the outside of the bar ,
so the bar ends go on carbon time trial aero bars.

The aluminum version of the Nitto Albatross is heat treated because of the thinwall tubing, but it's only thinwall for about 2". I found out the hard way when I shortened mine. I used a die grinder with a long burr to increase the inside diameter and modified my Simplex Retrofriction bar end shifters slightly.

http://inlinethumb14.webshots.com/44...600x600Q85.jpg

3 options:

- Turn down the shfiters
- Drill out the bars
- Different bars

Choose whatever you feel will be the easiest. Personally I would try a dremel grinding wheel inside the bars. You probably don't need to remove much material.

I had this problem once. I just laid some gritty wet-dry sandpaper over a cylindrical tube that fit inside...turned it a bit. took 20 mins, I believe.

I haven't looked at a set of Shimano barcons in years, but if they still use 3 sectors, it may be easier to modify the sectors than the bar.

Remove the expander bolt, and take the sectors out from the spring. Be gentle so you don't destroy the spring. Then file or sand a bit off the mating ends of each sector. This allows them to fit a bit closer together making the minimum OD smaller.

Reassemble and you should be good to go.

the flat head bolt , which has the allen hex socket in the end.

Can get a little taken off the edge of the head, that will also
potentially be interfering. and reduced a Bit.

I did this to fit some Shimano bar-ends in a thick wall aluminum handlebar. It look some filing and sanding, but it worked.

If you're near Portland, Oregon, talk to Terracycle. They custom-make handlebars for recumbents, and they know how to ream the handlebar for the shifter.