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Straight Handlebar length/cutting handlebar

Old 03-16-16, 01:43 PM
  #1  
El Gato27
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Straight Handlebar length/cutting handlebar

Bought a new to me 2016 Specialized Sirrus of Craigslist and I really like it, but the handlebar is too long. My old Nishiki hybrid has a 23" or 584mm handlebar, this new bike has a 28" or 711mm handlebar. Was wondering is anyone has ever cut a handlebar and if so what is the procedure. I've cut PVc pipe but pretty sure that won't work. Or should I buy a shorter handlebar?

Thank you.

Felix
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Old 03-16-16, 03:06 PM
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I've never done it but you need a pipe cutter.
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Old 03-16-16, 03:08 PM
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For Al bars, a pipe cutter will work. For steel, Al, and carbon a hacksaw is best. A guide makes it easy and a file deburs the edges.

Measure twice, cut once
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Old 03-16-16, 04:04 PM
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I cut about 1/2" off the ends of my handle bar. It made a world of difference in personal comfort.
It doesn't sound like much but you'll notice right away.
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Old 03-16-16, 04:11 PM
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With steel and aluminum handlebars, a pipecutter works best.
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Old 03-18-16, 09:15 AM
  #6  
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I've cut handlebars and used a hacksaw. I didn't have a pipe cutter. To determine where I cut them, I placed my hands straight out meaning that the distance between my hands was the same width as my shoulders and my arms were parallel to each other rather than angling away from my body.
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Old 03-18-16, 10:30 AM
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Originally Posted by practical View Post
I've cut handlebars and used a hacksaw. I didn't have a pipe cutter. To determine where I cut them, I placed my hands straight out meaning that the distance between my hands was the same width as my shoulders and my arms were parallel to each other rather than angling away from my body.
Wider shoulders do need wider bars but your technique would not work for all people; yours truly would be on 15" bars, which wouldn't even fit grips, levers, and shifters
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Old 03-18-16, 11:04 AM
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Originally Posted by DorkDisk View Post
Wider shoulders do need wider bars but your technique would not work for all people; yours truly would be on 15" bars, which wouldn't even fit grips, levers, and shifters
You make a good point. Before cutting, move in your brakes and shifters and make sure there's room for a bike computer and maybe a light. If you can, move in your grips too. If you're not confident, cut off less on each end than you think you'll want. You can always cut off more but you can't add length back.
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Old 03-18-16, 01:42 PM
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Originally Posted by sail View Post
I've never done it but you need a pipe cutter.
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Old 03-19-16, 06:46 AM
  #10  
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Originally Posted by avidone1 View Post
clever
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Old 03-19-16, 06:50 AM
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I've used a pipe cutter and a hacksaw. Either does the job perfectly.
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Old 03-04-17, 07:29 PM
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I didn't cut the bars. I move the shifters and brake levers in about an inch and a half.... moved the grips in accordingly, and set the bar ends at the ends of the grips, holding it all together. I have, then that empty bar sticking out, but since my mirror is out there, too, I'm not tempted to take a hacksaw to the bars. You might try something similar before getting out a saw. Just a thought.
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Old 03-09-17, 06:35 AM
  #13  
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i just used a hacksaw, worked fine for me!
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Old 03-22-17, 10:39 AM
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I recently bought a Sunlite aluminum riser bar to replace the flat bar on my Miyata Triple Cross. I'd know for some time that I like my bars no wider than 24", and the Sunlite's was 27-1/2". So I carefully measured and taped the cutting mark, and to my surprise, after amputating the offending excess, the interior of the bar had suddenly become double the thickness! No grip plug or accessory would fit into the diminutive hollow, and the bars were thus rendered "un-returnable." It took a few dismayed moments to realize that cutting-down the grip plug's fins with a pair of sharp scissors would effectively rekindle their marriage.

Last edited by Greggster; 03-22-17 at 10:44 AM.
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Old 03-22-17, 10:45 AM
  #15  
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I'm purely a hacksaw and file guy for cutting bars. It's an easy enough job, and there's no reason not to.

If you are a crappie sawyer, but two hose clamps. Put them on either side of the cut, and run the saw down the slot. Finished with a file to demurred and clean up the cut.
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Old 03-23-17, 11:53 AM
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Not everyone is fortunate enough to have a machine shop outside their office door but I would just take care of the excess with an abrasive cutoff saw. I read the OP's posting and realize he knows for certain what length he wants his bars but to anyone else reading this thread I'd recommend assembling the bars as is and trying out a new setup as Ray mentioned earlier.
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Old 03-23-17, 12:19 PM
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Originally Posted by MikeinMotion View Post
Not everyone is fortunate enough to have a machine shop outside their office door but I would just take care of the excess with an abrasive cutoff saw......
Another case of trapping a mouse with a bear trap. The tool is unnecessarily costly for the job, and for most folks harder to control than a hacksaw. It's also messier creating more dust spread farther.

IMO, hacksaws need a new press agent, they've become the Rodney Dangerfields of the tool world and don't get any respect.
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Old 07-15-20, 10:01 AM
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I just cut my carbon bars. One end I used a hack saw(32tpi) and the other end I used a 2x72 grinder that I have. The grinder took it down to what I need precisely and clean in less than 20 seconds. If you have one, that’s the way to go, if not, hacksaw works great too. Make sure it’s for carbon or 32tpi.
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Old 07-15-20, 10:43 AM
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Originally Posted by myemptymind View Post
I just cut my carbon bars. One end I used a hack saw(32tpi) and the other end I used a 2x72 grinder that I have. The grinder took it down to what I need precisely and clean in less than 20 seconds. If you have one, that’s the way to go, if not, hacksaw works great too. Make sure it’s for carbon or 32tpi.
Please wear a mask, i know everyone has one these days. Carbon fiber is toxic to humans, should wear it even with alloy or steel.
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Old 07-20-20, 12:29 PM
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Wink Cut my bars down a lot.

Hacksaw. Isn't hard. I used electrical tape as a wrap to guide the saw and bing bang, boom. Worked. Easy.


Originally Posted by El Gato27 View Post
Bought a new to me 2016 Specialized Sirrus of Craigslist and I really like it, but the handlebar is too long. My old Nishiki hybrid has a 23" or 584mm handlebar, this new bike has a 28" or 711mm handlebar. Was wondering is anyone has ever cut a handlebar and if so what is the procedure. I've cut PVc pipe but pretty sure that won't work. Or should I buy a shorter handlebar?

Thank you.

Felix
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Old 07-23-20, 01:57 PM
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+1) Same tool in the Bike Shop that is a saw guide (for cutting threadless steering tubes), works on cleanly cutting ends of handlebars ..
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Old 07-25-20, 11:11 AM
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This is a nice cutting guide; it has an egg shaped hole to secure various sizes. Useful for steerers, bars, and seatposts.
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