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Can I flop and chop aluminum bars?

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Can I flop and chop aluminum bars?

Old 06-17-08, 08:01 PM
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ScottNotBombs
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Can I flop and chop aluminum bars?

I have some Bontrager aluminum drop bars that I would like to flop and chop, but the metal seems really thin and I'm wondering if I'll run into any problems if I flop and chop them.
Just asking before I ruin some $60 bars... even though I got them for 99 cents on ebay.
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Old 06-17-08, 08:03 PM
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Shouldnt be a problem. I'm gonna do the same to the bars that came on my Windsor.
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Old 06-17-08, 08:06 PM
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Thanks.
It doesn't seem like it would be a problem, but I just wanted to double check.
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Old 06-17-08, 10:37 PM
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Definitely no problem chopping an aluminum bar. I just did it to an old aluminum bar I had lying around.



Good luck.
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Old 06-27-08, 08:26 AM
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just chopped these aluminum bars. i'll be getting some bar tape today.



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Old 06-27-08, 08:33 AM
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quick question, what do you use to chop the bars and what do you do to cap the end of it? just a regular saw?

i'm interested in doing this to my stock Raleigh Rush Hour drop bars..
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Old 06-27-08, 08:36 AM
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They won't feel like real bull horns do. And right now nashbar has their bull horns on sale for $19ish. IMO i'd just get the real ones and keep the drops for if you want to run drops later on.
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Old 06-27-08, 08:43 AM
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you can use a hack saw, but for a cleaner cut I always use a plumbing pipe cutter. They can be had at any hardware store for less than $10. Used these many times, never had an issue with them. Gives a very clean cut. only trick is using it on a curve if you are chopping road bars to bullhorns. Won't work as well at the curve. Look at photo of tool and your see why. If you plan on wrapping the bars with bar tape, the tape will come with end caps.
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Old 06-27-08, 08:45 AM
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Originally Posted by onespeed89 View Post
They won't feel like real bull horns do. And right now nashbar has their bull horns on sale for $19ish. IMO i'd just get the real ones and keep the drops for if you want to run drops later on.
I totally agree with this. The horns will be rather short compared to a production bullhorn and will offer less had positions. I just got really bullhorns after riding some short horned cut drops and feel much better about them.
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Old 06-27-08, 08:50 AM
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Old 06-27-08, 08:50 AM
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Originally Posted by zooyorkcity View Post
quick question, what do you use to chop the bars and what do you do to cap the end of it? just a regular saw?

i'm interested in doing this to my stock Raleigh Rush Hour drop bars..
I just did this on my Rush Hour's stock drops... I used a miter saw, it worked great. Then i just filed the ends down a little to smooth them out. The bar tape caps just fit right in, provided you didn't pinch the bars while you make the cut.
I've been meaning to post some pictures, i'll do it this weekend.
It looks great by the way...
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Old 06-27-08, 10:26 AM
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I did, they are fine
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Old 06-27-08, 11:57 AM
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Originally Posted by onespeed89 View Post
They won't feel like real bull horns do. And right now nashbar has their bull horns on sale for $19ish. IMO i'd just get the real ones and keep the drops for if you want to run drops later on.
After trying out the chopped bars, I want to get actual bullhorns. I hated the stock bars so I didnt care to use them again as drops.
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Old 06-27-08, 01:03 PM
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Use a pipe cutter to chop, then stick wine corks into the ends. They look nice.
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Old 06-27-08, 01:41 PM
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Originally Posted by timdoug View Post
Use a pipe cutter to chop, then stick wine corks into the ends. They look nice.
+10
nice one, i put some corks in my drops on my steamroller and the color of the wine stained end matches the frame color, it was so perfect
 
Old 06-27-08, 01:50 PM
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wouldn't you be ruining $0.99 bars
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Old 06-27-08, 03:45 PM
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Originally Posted by zooyorkcity View Post
quick question, what do you use to chop the bars and what do you do to cap the end of it? just a regular saw?

i'm interested in doing this to my stock Raleigh Rush Hour drop bars..
Plumbing pipe cutter. Shouldn't have any problem cutting aluminium handlebars - I cut my steel handlebars with it fairly easily.
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Old 06-27-08, 04:55 PM
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personally i prefer the flop n chops over some bullhorns.
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