Drilling carbon handlebars and carbon fork steerer...

Drilling carbon handlebars??

I want to drill a hole in carbon bars to fit di2 wires into a stem housing a junction box, 11 speed.

Good idea / bad idea, resin around the hole as a fix?

Then, I want to run the cables down the steerer and out of a hole into the top or down tube....

Whadda ya recon?

Teeth are overrated.

It's been done before. If you're careful and drill within the clamping area I can't see it making much of a difference #notanengineeroktechnicallyanengineerbutsoftwaredoesnotreallycountinthiscase

You will die

Of interest: https://www.lfgss.com/conversations/315753/ ?

Yeah thats exactly where I was imagining... The general idea led me here: http://nyvelocity.com/articles/equipment/cx-di2-live-build-with-mark-purdy/ but I have carbon bars and fork to contend with.

Nice, so a bontrager stem could help avoid drilling the bars and resin round the steerer hole could add some strength. Hole of 5mm to squeeze the connector through, or a 3mm hole, cut it and reattach...

The connectors aren't 5mm are they? That seems 'large'.

Yep 5mm says the internet

Yeah

http://weightweenies.starbike.com/forum/viewtopic.php?t=94395

Thinking about it, I filed out a hole but it was only for the wire diam. not the connector.

Someone on here has this sort of di2 set up on a Cielo, not sure if they had carbon bars though.

edit; it was @Jaap , looks like alloy bars though.

https://www.pedalroom.com/bike/cielo-road-racer-disc-21924

I want to drill a hole in carbon bars to fit di2 wires into a stem housing a junction box, 11 speed. Then, I want to run the cables down the steerer and out of a hole into the top or down tube....

Yes, I did exactly this with aluminium bars and a carbon fork (steerer). I have been fine for 3,5 years now, which included al kinds of gravel, mud, whatever some MTB trails threw at it..
Drilled the bars:


Drilled the steerer:

Had to use a Dremel with a grinding stone for the headtube:

Than had to pull the di2 wires through after I used some fishingline and lead:

Awesome, thanks for posting! I'll have a clear idea what I need to do when this arrives, for example how will a dremel react to Ti...

Great build by the way that's awesome bike

Thanks! You've got a nice one coming your was as well :)

Titanium is a bit softer than steel, so wouldn't be a problem. It took 7 grinding stones though..

Ti doesn't conduct heat well (for a metal), your tool will absorb a lot of the heat and wear out quickly.

And many alloys have a tendency to work harden.

Getting through the head tube with a Dremel could be troublesome, considering access.

Yeah it could be fun... project thread coming soon

Hi Japp, do you have any photos of how the wire runs from the stem & into the steerer, past the star nut?

None of that bothers me except the hole on the bend of the bars. That looks well sketch to me.

Yep not keen on that either, but then again I hardly ever use the drops...

I think the zipp sc70 ergos are the way to go on this over the fancy carbon bars I had imagined

Happily the head tube has holes leading to the down and top tubes... options

I'm sorry, I don't have any pictures. But I used this extra short expender plug instead of a star nut. Drilled at the lower part of the stem clamp in the steerer so it just clears the expander.

@hippy, I was lucky enough to have a whole crowd of people criticise me for drilling the bars. But after 4 years of real abuse they still don't have any cracks or signs of wear/stress/fatigue.

I have a SL70 ergo on my Cielo.

Ahh I get you