PITA lever to fit to bull horns but will it fit, will it%!?!

Posted on Fri 8th, July 2011

• #1

VanUden

OK, I have a tektro time trial lever for bull horn bars to fit bars with an internal diameter of 18.9mm up to about 20mm. I have bull horn bars with an internal diameter of 19mm (according to my cheapo micrometer) but will they fit together? Will they feck.

When putting them together they're 'on the edge' of fitting but not if that makes sense? I've been at the inside of the bars with the dremel and removed all paint, also removed a small amount of ally (just sanding) but still no joy. How much material can I remove without jeopardising the bar? I reckon a fraction of a mm more and it 'should' all fit together...
• #2

lae

I had the same problem. If it really is just 0.1mm then I'd sand it - I doubt the manufacturing tolerances are that high anyway. Extruded aluminium tends to have poor notch sensitivity (i.e. if an alu bar has a notch, scratch/gouge or sudden change in thickness, it can be particularly weak compared to steel) so I would sand it by hand to get a smooth gradient.
• #3

VanUden

Cool, thanks lae will get the needle files out then finish off with wet and dry :)
• #4

lae

I used coarse sandpaper wrapped around an inner tube wrapped around a piece of wooden dowel, so it was only just narrower than the ID of the bars. A novelty giant pencil would also work.

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