MTB handlebar extension plugs

thingiverse

I designed a quickfix for my my too narrow MTB handlebar. The extensions measure 15 mm each, so the bar gets 30 mm wider in total. The outer diameter is Ø 22.2 mm – regular handlebar dimensions, the inner diameter is Ø 18 mm --> check the inner diameter of your bar. If it's smaller than Ø 18 mm this extensions won’t fit. The mechanism works as a regular top cap expander used for carbon fork roadbikes. As you tighten the allen screw the two conical parts move towards each other and spread the slotted middle part which presses against your inner handlebar wall. I mounted some ESI foam grips and so far I have done about 15 rides, two days bike park included. The extensions work unremarkably, didn’t get loose or anything. They also took a beating in a crash and probably saved the edge of my bar. Since the extensions are on the very end of your grips, there is almost no body weight / load applied. But the longer you design them, the bigger the load will be and also the lever forces on your bar. That’s why I went for a 15 mm and not a 20 mm version. But of course: usage at your own risk! You have to print all parts standing upright with 100 % infill. Choose enough perimeters so that themiddle part only consists of perimeters and no regular infill. I used PLA plus from filamentworld - this stuff is way stronger than regular PLA, though a bit pricy. For assembling you’ll need two stainless steel: • M5 x 45 mm allen screws • M5 locknuts • M5 washers (ø 5,5 mm / Ø 9,7 mm) Press each nut into the inner part and put some grease onto the conical, sliding surfaces to reduce friction while tightening the plugs. Enjoy your rides! cheers