Lightweight press-fit MTB handlebar plugs

cults3d

There are already plenty of handlebar plug designs available on Thingiverse, along with some excellent models. This particular design stands out for its exceptional quality and I've had the chance to print and use it on several bikes. The main issue I have with most existing designs is that they're either too heavy or don't fit my bars properly. To address these issues, I spent several months experimenting with different design variations and testing them extensively. The design itself is incredibly minimalist - the outer diameter of the plug measures 22.2mm (7/8"), matching the outer diameter of MTB handlebars perfectly. This allows the plugs to stay securely in place even when grips are installed or removed. The design is tailored to fit snugly within the inner diameter of the handlebars, which you'll need to measure carefully. If you're unsure about the size, simply print several versions and see which one fits best - for instance, I found that the 17mm size worked perfectly on both my ENVE bars and my wife's Bontrager XXX bars. I also discovered that the aluminum bars on my XC bike had thinner walls, so they required the 19.5mm diameter size. To make things easier, I've included STL files for a range of sizes from 16.5 to 20mm. If you need more customization options or want to make any further changes, the Fusion360 F3D file is also available. As you can see from the photos, these plugs are incredibly light - even the largest size weighs just 2.5g in PLA. While this might seem excessive for some, I'm not aware of any other option that's lighter without compromising safety. Of course, if you're willing to spend more money, you could opt for a set of carbon fiber plugs, but at over double the weight, they're hardly worth it.