Bar end plugs/reinforcement/BERTS

[jonthefish]

I just got a lovely set of lightweight Titec Ti bars for a build (thanks Murray). I want to mount bar ends but the bars didn't come with the BERTS - the reinforcing plugs to prevent damage. Any advice what should be using?

 

[jonthefish]

Anyone found/made suitable end plugs for attaching bar ends to thin-walled Ti bars?

Looks like the original reinforcement plugs/BERTS were quite thick walled. http://pedaldamnit.blogspot.com/2006/09/titec-118-tale-of-2-berts.html

 

[ferrus]

Which version of the Titec bars do you have? - the 118s are incredibly thin walled and would definitely need support, but the regular ones should be fine without, if you're not over zealous with the allen key.

If you do need the plugs, I wouldn't be too concerned about the spec's. As long as they're a reasonably close tolerance fit and don't rattle about (slight deformation of the bar when clamping will hold them in place), 20 - 30mm long and a mm or two thick they'll do the job.

The 118 are slightly prone to bending in a crash, but the ends are quite hard to permanently deform. They’re fantastic bars!

 

[jonthefish]

They are 118 bars. So very thin. I am thinking that metal inserts/plugs are needed but haven't seen anything "off the shelf" that looks suitable.

 

[ferrus]

No other bar is so thin walled! - so the plugs would be wider than for other bars. Any machinist could turn some for you for a few quid

 

[ferrus]

FWIW I have two of these and they both came with the longer, thinner-walled BERTs. They’re a slightly loose fit but tighten up when bar ends are fitted.

118s are really strong so the inserts just need to provide a minimal support to stop the bars from squashing/deforming. I’d feel confident using just solid hardwood plugs, but someone with a lathe would make some alum ones

 

[jonthefish]

Thanks Ferrus. I had vaguely wondered if I could make some from oak - I cut heaps for firewood! Might try local machine shop first though.