handlebar extensions: Anyone got a better idea?

docnjoj

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Fairhope AL
I had to extend my handlebars when I went to 20" front wheels so I found these pipe repair fittings. They make them hinged which will look a bit better but I would love a CNC fitting for 7/8" (22.3mm) bars that connects the new section to the old one. Don't wanna weld on the bars. Any ideas?
otherDoc100_4723.JPG100_4724.JPG
 
Thanks DS. I kinda did that with the extension being the same diameter as the bars but I hate the way it looks. I could do a larger alloy tube over the bars but then none of the brakes or shifter (bar end) or throttle fit. They are all made for 22.3mm bars.
otherDoc
 
I just found a better idea! 2 of these around a 1" alloy tube about 4" long should make a good clamp for the extension. Looks good too! Ain't the internet wonderful since it is coming from a Unicycle shoppe!
otherDoc
nimbus2boltclamp.jpg
 
That's one fitting to use.

I also would've suggested fitting a tube inside or outside the bars and clamping it down; I'd've used something like seatpost clamps for that part. I have a few ideas for projects that involve such things to create the tube extensions I will probably need for steering stems and the like.

Another way I planned to do it was find some bars or other tubing (like bedside potty chairs) that are slightly smaller diameter, but not quite small enough to fit inside, and then cut a slit down the length of the smaller tube. Just make sure the slit is barely enough to allow the tube to insert inside the bars, so that it's edges come together inside, preventing it from loosening if lateral pressure is applied on the bars.

Hammer that down into the extension bars halfway, then hammer that assembly down into the original bars, using a tool from the inside if necessary to push on the internal slitted tube so it doesnt' slide further into the extension bars. No welding, and in theory can still be removed but would almost certainly never come out or shift on it's own.
 
Forget the ugly or expensive clamps. Find a piece of tubing that fits neatly inside and epoxy it in the extension first with 1/2 sticking out, which you do away from the bike to avoid mess. Then epoxy (or clamp or run a bolt thru to secure if it needs to be removable) the extension in place, which slides into and mates cleanly with the original tube.
 
Thanks AW and John. Normally I would weld on an extension but I want to leave the trike returnable to it's original form. I decided to go with the external aircraft alloy tube 1" OD cause I have some. The ID is about .2mm bigger than the handlebars so it is a snug fit. Slots and clamps should make it strong. With the clamps it should look pretty also. I'll post pics when it is complete. My wife saw the order and emailed me if I was getting a unicycle. I wrote back that it was for my "end of life crisis"!
otherDoc
 
here are some collars from xtracycle that might work-very clean.

http://www.xtracycle.com/cargo-bicycles/cargo-bike-accessories/whatchamacollar.html
 
Thanks Will! I saw those but they were twice the price of the unicycle ones. Also they don't give dimensions so it might mean I would have to shim. More work! They are nice looking, though and probably well engineered.
otherDoc
 
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