Lauterwasser handlebar project.
 

The topic of these handlebars came up a while ago. Since I have a Lauterwasser handlebar, a mandrel tube bender and some 7/8" 4130 tube I figured I might also have some usable tooling. After committing to the filth that goes with bending dies (lots of oil on this stuff) I found the required die sets and went to work.

My tube bender is partially home made. The original must have been for smaller tasks because it broke nearly every time I tried to use it. Eventually I replaced the entire drive system with a giant bicycle type chain. Here is a film of it bending a 2" diameter tube (sound is mandatory for this one)

http://www.flickr.com/photos/frankth...7623874107330/

As you can tell, it's a monster.

With this type of project, you can tell how 99% of it is going to go. (1) waste a lot of material (2) use a lot of time (3) Fail.

Steel handlebars made in the 30's would have been made from different material (We know people are trying and failing to make this in mass production so they can figure this out themselves) that is easier to fabricate so I wasn't too confident.

I ended up blowing through 24' of tube and finally getting something I liked. The center is sleeved on the inside, full-pen welded and will get another 1" sleeve brazed on the outside.

The end on the grip bend has a pretty big ripple that I am not stoked about. They ended up within 1/4" of the original profile. Nice-

http://farm6.static.flickr.com/5046/...ff26b3ec59.jpg
IMG_4003 by frankthewelder, on Flickr
http://farm6.static.flickr.com/5129/...d4ae635b05.jpg
IMG_4004 by frankthewelder, on Flickr

Wow, very cool. You certainly seem to have some serious fabrication skills.

Nice work, Frank. I think rhm is going likely headed up your way right now to get one!

Neal

Frank, this is good news indeed!

I recently got a couple Bike Nashbar mustache bars, which are 15/16" chrome moly steel, with an eye to bending them into a Lauterwassery shape. I did the first one last weekend, using old MTB stems and, as cheater bars, the tubular steel legs from an old conference table. The technique was to mount the two stems a short distance apart, and bend them away from one another; giving me a series of ripples, one between every two places I mounted the two stems. The overall look is good... but yours looks much better.

The bending machine certainly is a monster! Sort of a flatulent one.

Your little YouTube clip is interesting Frank. Thanks.
( I don't think this is a thing that very many of us could construct though - no matter how many mysterious shaped metal objects we might have squirreled away).

Wow, Frank! Serious props are due. That bar looks really good.

Obvious question Frank... Will you end up selling some???

Never mind.

Yes, thanks. Duh. I will edit my post.

There was a blog from Soma regarding their attempt at one of these. Dunno if they ever actually produced anything though.

Oh man that is awesome! Very well done.

Sweet! Let me know when you start selling production models:D

We have a tubing bender for exhaust and roll cages, not sure if we have dies small enough to do handlebars, might be worth checking into.

Aaron :)

Thanks for the compliments, I usually make these type of items for myself. I don't have the endurance or ambition required to produce quantities of anything. People buy items and I make a living but mostly doing one-off stuff or very limited production at near one-off prices.

All I have to say is WOW!

Awsome job!!!
Oh how I wish I had the skill and the means to play as you do.

Frank, where are you in Vermont? I visit Vermont every February, and I was there in August this year, too.

Nice job on the Lauterwassers.......looks like you'd have some takers if you decided to make a few.

I am in Bellows Falls, one exit up from Putney on 91. I think you would enjoy my shop. Lots of old bikes and machinery.

Those won't work and the dies aren't available in the correct radius.

Ain't no "think" about it. I KNOW I would love your shop. And you're right off the interstate, so I will see if I can stop by. We visit Plymouth (near Rutland) in Feb.

I sent you a couple of emails. Have you seen them? I want to help with the Golden Arrow.

When you stop for the tour of FTW Industries, let me know, I'll pop on over from NH and join in the fun!

That's a great idea, Pastor Bob!

you two are going to bring cameras and report on this trip...right? Those of us trapped on the tropical Left Coast can only dream about the wonders you'll see....:)

Soma Fabrications is producing a retail Lauterwasser now. $73.99.

Tom, yes I got your email. I found a couple of K-series hubs in UK and am torn between a rebuild and a replacement. My rim is also shot.


Perhaps we should have a open house based on your travel plans. There is some odd chance we could ride but not likely. People can braze or TIG weld or just view a demo ( I think I have a large screen somewhere), mitre some tubes or whatever. I have a few bikes and some parts so we should consider that and have a swap.

Built into my building is one of the oldest structures in the area and my building is very old. It's not pretty but it is amazing.

I am in the 05101 for those who might consider visiting.

It looks like they have a ways to go also. They are aluminum, wrong bend radius. I should post the info of where you can get those for $2.00 LOL.