Trimming Handlebars?

Reply Subscribe

Thread Tools

Search this Thread

Jun 7, 2016 | 11:18 AM

Jackpoticorn

Thread Starter

Road Captain

Joined: Jun 2014

Posts: 508

Likes: 31

From: California

Trimming Handlebars?

Maybe a dumb question - but is it really as simple as taking a store-bought pipe cutter to the end of handlebars to trim them down? Or does it require more intense tools? I'm looking at a couple different tracker style bars but the ones I like the most are about 3" too wide for what I want. Thought?

Jun 7, 2016 | 11:44 AM

cggorman

Extreme HDF Member

Joined: Jun 2014

Posts: 11,448

Likes: 2,299

From: NW Ohio

Depends on the wall thickness. I wouldn't expect good results with .120 DOM. Either way, you'll roll in the cut pretty bad and might need to re-expand it and deburr the inside.

Lacking proper power tools, I'd do it with a hacksaw before a tube cutter.

Might also take them to a metal fab shop and have them chop them off.

Be aware that you may cause the wiring dimple to become unusable. Not a big deal if you plan to wire internal, but worth noting.

Jun 7, 2016 | 11:46 AM

nevil

Seasoned HDF Member

Joined: Jul 2008

Posts: 9,282

Likes: 1,139

From: southeast PA

In the past I've used a hacksaw with a good blade to cut steel. Then just file or debur the rough edges when done.

Jun 7, 2016 | 04:29 PM

Tommy C

Seasoned HDF Member

Joined: Oct 2015

Posts: 13,529

Likes: 34,709

From: Pine Flat Dam/South Bay Area, CA

Use a piece of masking tape on the bars for a guide & use a hacksaw or sawsall to make the cut. De-burr with a file & you are good to go.

Jun 7, 2016 | 06:21 PM

CJD197

Tourer

Joined: Feb 2016

Posts: 309

Likes: 39

From: Southlake Texas

My new "favorite" metal cutter is a 4" grinder with a cutoff disc. You'll have it off in less than 10 seconds!

Jun 7, 2016 | 08:22 PM

rednred

Tourer

Joined: Jul 2013

Posts: 338

Likes: 44

From: Colorado

I used pipe cutter, went slow and had zero problems. Lengthening holes for internal wiring was much greater challenge but still not too bad.

Jun 7, 2016 | 08:56 PM

F86

Outstanding HDF Member

Joined: Mar 2015

Posts: 2,840

Likes: 900

From: Philly Suburbs

I've done it with a pipe cutter as well. Just keep tightening it, make sure that it doesn't "walk" while you get it started, and be patient. It actually works pretty well. It can take a little bit of cleaning up with a file, but less so than when using a hacksaw, in my experience. I found that the cut stays much straighter against the bar than is true with a hacksaw. Once a reliable, even groove is achieved, you can use a little bit of lubricant of some sort.