How to: Cheap metal bar ends

[ChinnyBKR]

Required:

2x Plastic Bar ends
2x Undeformed beer bottle caps
2x Headset spacers
Epoxy may be needed.

Tools:

A spark plug socket
A hammer
Screw driver
Hand saw
A pin or a drill

1. First take your bottle cap and enlarge it so you can fit it in the headset spacer with your spark plug socket.
2. With the cap on the socket, press the cap into the headset spacer so its snug. If it's loose, you may want to use some epoxy.
3. Drill a hole in the center large enough for the bolt to pass through, counter sink this if desired. Repeat for the other end.
4. If your bar end is 1 solid piece then proceed to step 4a. If the cap is detachable from the wedge, go to step 5.
4a. Take your saw and saw off the cap and only the cap.
5. Disassemble the bar end and chuck the cap, you only need the wedge part.
6. Put the bar end together and install on your bike.

PICS:




Sorry for the horrible pics, night time + cell phone cam = a big no no.

[ian]

i just make mine is metals shop class. right now i can make them out of aluminum or plastic. but my friend is working on injection molding bar ends so we can produce many at one time with out the cost. ive been lazy and havent made guts for the bar ends yet, but i have plenty of caps!

[pinkfluffymunky]

is it easy to make them out of aluminium....i might make some in tech if is only takes a small amount of time

[pinkfluffymunky]

i've thought of an okay design....would take 2 mins....
cut out a circle (diameter of bar) with bout 1/2"-1" length arms coming out of it....bend themat a right angle to the circle and then slide the arms under the grips......the only bad point is really that if your grips arent tight it wont stay on