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Home Made Handlebars Material Selection Help

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Home Made Handlebars Material Selection Help

Old 10-30-22, 11:09 AM
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degull
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Home Made Handlebars Material Selection Help

Hi everyone. I would like to bend my own handlebars for personal use. I have a Diacro bender and I have made some dies for it.
I was planning to use .049 chromoly from Aircraft Spruce but Im wondering if .049 is too heavy/overkill for handlebars? I weigh 150lbs and the handlebars will be used on a city bike.
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Old 10-30-22, 10:09 PM
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IIRC Tioga used .035 walled bars back in the day. Steel bar failures are rare and usually able to see the seeds of cracks before the catastrophic happens. How wide will your bars be? How will the stem clamp diameter spec be handled? Andy
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Old 10-31-22, 09:49 AM
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Originally Posted by Andrew R Stewart View Post
IIRC Tioga used .035 walled bars back in the day. Steel bar failures are rare and usually able to see the seeds of cracks before the catastrophic happens. How wide will your bars be? How will the stem clamp diameter spec be handled? Andy
I was going to experiment with different bends and angles. The bars will be installed on a city bike so I wont go wider the 44cm. For the clamp, I was going to turn an aluminum shim and cut it half. I have toyed with the idea of making a bullmoose bar with a 1 1/8 stem clamp.
I dont have any chromoly handlebars to measure the wall thickness. I have .035 wall so I might give it a try.

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Old 11-08-22, 10:58 AM
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The weight difference between 035 and 049 is not worth how much worse the bends will look if not using a mandrel bender.
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