Bicycle handlebar extender for experimentation

thingiverse

Have you ever wanted to experiment with wider handlebars without making the commitment of buying a new handlebar at the risk of not liking it? These handlebar extenders can be used to to just that. WARNING! It is not intended as a permanent solution, only to try them out on a chill ride around the neighborhood, and unless you dont go crazy on the extension length, you should be fine on said chill ride. I would not go more than 15mm on each side. This is of course done completely at your own risk. Don't go bomb down a mountain with these! The design was done in freecad, all parameters are adjustable with the spreadsheet in the project. The extenders are secured in the handlebar as follows: - Use a bolt with the following minimum lenght: extension_len - countersink_depth + insert_len + 20mm + washer_thickness + nut_thickness. - Cut a strip from an old innertube with dimensions of approximately 250 x 20mm - insert the bolt through the insert, add a washer with a diameter slightly below the inner diameter of the handlebar, but still fitting loosely. Add your nut. - wrap the inner tube around the bolt between the insert and the washer. when you are done, the diameter of the wrap should be roughly the same as the washer diameter. Trim or add as neccesary. - tighten the nut enough so that the washer gets put up against the nut by the wrapped tube and glue the washer to the nut with some instant glue. This is to prevent the nut from slipping, you don't need a lot. - when the bolt is tightened, the innertube wrap gets compressed between the washer and the insert, bulging outwards. This keeps it in place in the handlebar. Tighten the bolt a bit before you insert it into the handlebar, just to get the bulging started. The friction of the tube aganst the washer should prevent it from slipping as you tighten the bolt. See the pictures for clarification. The included model is a 15mm extension for a 22mm handlebar with a 19mm inner diameter. It extends 15mm into the handlebar. I used a 50mm M6 hex bolt.