Bar end shifter

thingiverse

The pod has an insert that will support a standard shift housing ferrule. The shifter is oversized to pull enough cable for rear derailleurs like the Shimano Dynasys mountain RDs or 11s RDs, which require more cable than regular RDs. You might have luck swapping in your own shifters taken from stem or downtube units, but the cable stop will certainly not be aligned anymore, causing cable rub on the pod and eventually wearing through the plastic. I intend to design a second version of the pod so that the cable stop is aligned with a regular shifter. The shifter currently in place is 30 mm in diameter, while standard shifters are about 20-25 mm in diameter. It will still work with regular RDs, but it will pull more cable per degree of rotation, making it possibly too sensitive for most people's taste. 12 Dec 2016: Work in progress. Never tested this yet. I'm aware that the ferrule extruded cut is a little too deep right now and needs to be fixed eventually. Possible upcoming improvements include: * Resizing for standard friction shifters * Adding a stop on the pod for use with standard friction shifters at low setting * Reducing the extruded cut for ferrule inset * Introducing dummy downtube boss + Retroshift/Genevalle-style insets to provide a better fit with standard friction shifters * Inseting a washer for the shifter-pod interface on both the shifter and pod so that the channel and cable stop are still aligned How I Designed This Based on Suntour and Microshift bar end shifters, which should fit in the ends of most handlebars. Assembly & Materials Hardware needed: 4 mm bolt and locknut, appropriate o-ring for the plug assembly. Add washers where necessary to minimize friction between the shifter-pod interface. 6 mm bolt and nut are also required, with the 6 mm bolt controlling the plug assembly and its nut slotting into the expander piece inside the handlebar. The 6 mm nut is 3.79 mm in diameter, so the insert width in the expander unit is 115% larger. Printing: The expander piece has a six-sided slot (cut out on three sides) for a 6 mm nut. Print the expander with the slot facing upwards to eliminate supports inside. It's nearly impossible to remove supports from this piece without breaking it otherwise. A plug assembly is provided to streamline printing. Use this and orient it vertically to reduce supports. If you print each plug on its side, separately, the exterior round won't be as nice. You'll have to file it down. Updates 17 Dec 2016: Replaced the expander SLDPRT and STL. The old one's slot for the nut was too small. 18 Dec 2016: Added pictures of the first test assembly. The resize I did the day before worked. The slot is now a little too wide for my taste, but the nut is secure and doesn't slip when tightened.