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PostPosted: Thu Mar 20, 2008 1:05 am 
Dirt Disciple

Joined: Sun Mar 09, 2008 9:03 am
Posts: 30
I'm rebuilding my old Claud Butler (see separate thread) and the new Charge bar tape arrives soon.

The current bars have Shimano 105 Aero levers (just brakes, gears are on the downtube) but as they had the old foam "Grab On" grips the cables have been routed inside the bars, with the appropriate holes drilled at the cable exit points and just behind the levers themselves.

Is this OK? Is it safe? Or do the bars need chucking away, and cables should be run under the tape on new bars?

Thanks!


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PostPosted: Thu Mar 20, 2008 8:02 am 
The Guv'nor
The Guv'nor
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Joined: Sun Jul 03, 2005 11:19 pm
Posts: 23175
Location: Retrobike HQ
Never heard of this being done before. Personally I'd bin the bars for what a new set cost and what the implications of bar failure are. Be interested to hear from others if this was ever a common practice...


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PostPosted: Thu Mar 20, 2008 8:10 am 
King of the DuckBoard
King of the DuckBoard

Joined: Sun Jan 28, 2007 12:30 pm
Posts: 21466
I'd pass too. get new bars. But just one detail, was this drilling done by the maker? Or an 'ex' owner? But if not sure then for the price of a bad injury buy a new bar.


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PostPosted: Thu Mar 20, 2008 9:05 am 
Old School Grand Master

Joined: Tue Oct 09, 2007 1:55 pm
Posts: 8202
Location: New Forest, UK
Definitely dangerous...modern bars have grooves for the cables as experience showed that drilling was inadvisable - and bars these days are even thinner.


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PostPosted: Thu Mar 20, 2008 10:39 am 
Retro Guru

Joined: Fri Apr 28, 2006 8:42 pm
Posts: 783
Location: Brighton
The very act of drilling causes surface imperfections to be created which are the starting points for crack propagation. So any drilled hole must be polished to within an inch of its life afterwards if the life of the component isn't to be affected.

I've used aero levers on bars without the groove before. Just insulating tape the brake cables in a position where your hand doesn't naturally fall and then stick something like Phat Wrap on the bars and you'll never know they're there.


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PostPosted: Thu Mar 20, 2008 10:43 am 
Dirt Disciple

Joined: Sun Mar 09, 2008 9:03 am
Posts: 30
Nice one, thanks.

In the bin they go then!


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PostPosted: Thu Mar 20, 2008 4:35 pm 
rider | rBoTM Winner
rider | rBoTM Winner
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Joined: Fri Jan 25, 2008 1:42 pm
Posts: 5131
Location: Wakefield, Yorkshire
Drilling bars for concealed brake cables was a common 'trick' in the 80's before grooved bars came on the market. I know, I did it myself. I've never had one fail on me (thankfully!) but I've known ones that were home drilled fail on other people, generally without to much harm - but there's always a first time!

If it's a bike that will be used in anger and not show then fit a new pair just in case! Better to be safe than sorry.

PS - some manufacturers actually sold bars ready drilled, I don't know how they stood up to usage.


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PostPosted: Thu Mar 20, 2008 7:27 pm 
Devout Dirtbag

Joined: Tue Aug 21, 2007 6:12 pm
Posts: 107
Location: North Notts
I had my bars drilled in the 80's for dia-compe aero levers - cinelli bars. The bar snapped clean off near the centre sleave whilst pulling on them going up hill on a time trial :shock: :shock:
Made the ride home interesting :)
As you've said - bin em not worth the risk.


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PostPosted: Thu Mar 20, 2008 10:13 pm 
Old School Hero
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Joined: Thu Feb 21, 2008 10:04 pm
Posts: 192
Location: Up North
I use some old sr championship bars with this mod and never had any problems and actually it gives a very clean look. Like others have said, a popular mod in the 80's.


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