Convert drop handlebars into bullhorns

By parkr on Thursday, May 22 2008.

Bullhorns are a popular addition to any bike. They confer a clean, sleek look and a comfortable riding position, offering improved visibility in traffic. Whilst many different styles exist on the market, this article will describe how to convert an existing pair of "drop", or road handlebars into bullhorn bars. The technique is known as chop-and-flop.

Tools required

You will need...

An existing pair of steel or aluminium handlebars - do not attempt this method with carbon bars
A pencil or marker
Basic bike tools
A hand pipecutter and/or hacksaw from any hardware store

1. Remove the handlebars from the bike

You should remove any handlebar tape, end-plugs or grips. These should be retained if you wish to reuse them, or discarded otherwise. Then remove any brake levers, shifters and other attachments from the handlebars. Basic tools will be required.

Loosen the handlebar clamp and slide the handlebars out from the stem. If the handlebar clamp can be removed completely, this will ease removal. Check the handlebars thoroughly for any signs of damage or corrosion. Seek advice from your local bike shop if you are in any doubt.

2. Cut the handlebars to length using the pipecutter

Turn the bars over. You will use the pipecutter to cut the bars to length. It was found that pipecutters give a superior cut, but a hacksaw can be used instead. Mark one side of the bars to the appropriate length depending on your desired hand position. Remember the maxim: measure twice, cut once!

Smoothly tighten the cutting wheel on the bar until it begins to bite. Now rotate the cutter around, lightly scoring the metal. If the cutter will not rotate fully because it clashes against the bar, you may need to do a pre-cut using the hacksaw or just use the hacksaw instead. Continue to rotate the cutter, gradually tightening the wheel until the cut is made.

Once the cut is made, take the offcut and use it to mark off the opposite side. Repeat the cut on that side too.

Debur both ends, to remove any sharp edges. This can be done using a file, or tool supplied with the pipe cutter.

3. Reinstall your new bullhorn bars

Reinstall your new bars on the bike. Check the hand position is comfortable and adjust the angle if necessary. Reinstall the brakes and add handlebar tape to taste.