Handlebar shim DIY
09-14-15 | 04:48 PM
#1
Thread Starter
Senior Member
Joined: Aug 2009
Posts: 7,723
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From: Berkeley, CA
Bikes: 72 Cilo Pacer, 72 Gitane GT, 72 Peugeot PX10, 73 Speedwell Ti,l, 75 Peugeot PR-10L, 80 Colnago Super, 81 Zinn, 85 ALAN Cross, 85 De Rosa Pro, 86 Look 753, 86 Look KG86, 89 Parkpre Team, 90 Parkpre Team MTB, 90 Merlin
Handlebar shim DIY
I'm not sure if everyone goes about it the same way, but I thought I'd document the handlebar shim I made yesterday. After not finding the right one for sale at any of the bike shops nearby, and not wanting to wait for something to ship, I fabricated my own. In this case, needed a .4mm shim to mate my 26.0mm Modolo bars with a 26.4mm Cinelli stem. I had some .5mm aluminum sheet stock on hand already. First I measured the stem at its widest point. I then cut a strip of aluminum sheet stock that width but slightly longer than the circumference of the bars and then sanded the strip of aluminum with 400 grit sand paper until it measured approximately .4mm, which didn't take very long.
Then I wrapped the handlebar sleeve with the shim, and did a test fitting. You can do it just with the stem, though the photo below shows a test fit with both the bars and stem since I wanted to test the thickness as well. Most stems have a curve to the clamp area (to allow for installation). You want to maximize the contact area of the shim to the clamp area, but it's unsightly to have the shim extend beyond the stem. So, a little trimming is necessary.
First I mark the excess area of the shim with a sharpie pen.
Then trim the excess first with some wire cutters.
Then I used a circular sanding drum bit to remove the rest, along with another sanding with 600 grit paper to remove any burrs from the edge of the shim which might scratch the handlebars.
Polish up those bars if they aren't anodized and install. I've used Nitto shims and cut up soda cans, but it's nice to have the clean lines and security of a good fitting shim.
Then I wrapped the handlebar sleeve with the shim, and did a test fitting. You can do it just with the stem, though the photo below shows a test fit with both the bars and stem since I wanted to test the thickness as well. Most stems have a curve to the clamp area (to allow for installation). You want to maximize the contact area of the shim to the clamp area, but it's unsightly to have the shim extend beyond the stem. So, a little trimming is necessary.
First I mark the excess area of the shim with a sharpie pen.
Then trim the excess first with some wire cutters.
Then I used a circular sanding drum bit to remove the rest, along with another sanding with 600 grit paper to remove any burrs from the edge of the shim which might scratch the handlebars.
Polish up those bars if they aren't anodized and install. I've used Nitto shims and cut up soda cans, but it's nice to have the clean lines and security of a good fitting shim.
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-Randy
'72 Cilo Pacer (x2) • '72 Peugeot PX10 • ‘72 Gitane Gran Tourisme • '73 Speedwell Ti • '74 Motobecane Grand Jubile • '74 Peugeot UE-8 • ‘80 Colnago Super • ‘81 Univega Super Special • ‘82 Zinn • ‘84ish Mystery Custom • '85 A.L.A.N Cyclocross • '85 De Rosa Pro • '86 Look Equipe 753 • '86 Look KG86 • '89 Parkpre Team Road • '90 Parkpre Team MTB • '90 Merlin Ti
Avatar photo courtesy of jeffveloart.com, contact: contact: jeffnil8 (at) gmail.com.
-Randy
'72 Cilo Pacer (x2) • '72 Peugeot PX10 • ‘72 Gitane Gran Tourisme • '73 Speedwell Ti • '74 Motobecane Grand Jubile • '74 Peugeot UE-8 • ‘80 Colnago Super • ‘81 Univega Super Special • ‘82 Zinn • ‘84ish Mystery Custom • '85 A.L.A.N Cyclocross • '85 De Rosa Pro • '86 Look Equipe 753 • '86 Look KG86 • '89 Parkpre Team Road • '90 Parkpre Team MTB • '90 Merlin Ti
Avatar photo courtesy of jeffveloart.com, contact: contact: jeffnil8 (at) gmail.com.
Last edited by gaucho777; 09-14-15 at 05:50 PM. Reason: replaced wrong photo + fixed typo
09-14-15 | 07:13 PM
#2
Abuse Magnet
Joined: Jun 2012
Posts: 1,881
Likes: 188
From: Colorado
Bikes: '91 Mtn Tek Vertical, '74 Raleigh Sports, '72 Raleigh Twenty, '84 Univega Gran Turismo, '09 Surly Karate Monkey, '92 Burley Rock-n-Roll, '86 Miyata 310, '76 Raleigh Shopper
That's pretty slick work.
09-14-15 | 08:26 PM
#3
Senior Member
Joined: Aug 2006
Posts: 7,643
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From: Portland OR
Bikes: 61 Bianchi Specialissima 71 Peugeot G50 7? P'geot PX10 74 Raleigh GranSport 75 P'geot UO8 78? Raleigh Team Pro 82 P'geot PSV 86 P'geot PX 91 Bridgestone MB0 92 B'stone XO1 97 Rans VRex 92 Cannondale R1000 94 B'stone MB5 97 Vitus 997
Sweet frame!
I had the same issue, 26.0 bar into that same 26.4 stem. I happened to be drinking a can of Guinness. Deed followed thought and the shim was installed before the last swallow cleared my throat. My handiwork is nowhere as tidy as yours.
I had the same issue, 26.0 bar into that same 26.4 stem. I happened to be drinking a can of Guinness. Deed followed thought and the shim was installed before the last swallow cleared my throat. My handiwork is nowhere as tidy as yours.
09-15-15 | 12:03 AM
#5
Bike Butcher of Portland
Joined: Jul 2014
Posts: 12,486
Likes: 8,054
From: Portland, OR
Bikes: It's complicated.
Someone's gotta say it.
Zen and the art of Shim Making
Zen and the art of Shim Making
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If someone tells you that you have enough bicycles and you don't need any more, stop talking to them. You don't need that kind of negativity in your life.
If someone tells you that you have enough bicycles and you don't need any more, stop talking to them. You don't need that kind of negativity in your life.
