How to Make Chopper Bicycle Handlebars Out of Old Handlebars

How to Make Chopper Bicycle Handlebars Out of Old Handlebars
Taking old bike parts to fashion into new and different purposes saves natural resources and money. Bike builders can easily save these resources and money by making chopper bicycle handlebars out of old handlebars. With a simple set of tools, an afternoon to cut and sand the old handle bars, and a few hours spread over a couple of days to paint, this project yields a functional and strong set of chopper bicycle handlebars.


Difficulty: Moderate

Things You’ll Need:
  • BMX handlebars
  • Saw
  • Grinder
  • Sandpaper
  • Primer
  • Paint
Step 1
Remove the BMX handlebars from the bike and strip it clean of grips and bike accessories.
Step 2
Cut the crossbar from the handlebars. The crossbar is the extra bar that holds the pad and reinforces the BMX handlebars for stunts. To minimize grinding, cut close to the main bars.
Step 3
Grind the sharp edges and burrs from the crossbar cut. Make sure to grind the welds off. Grind down until the remaining handlebar tubes are round. Be careful not to grind into the remaining bars --- this could weaken the handlebar.
Step 4
Sand the handlebars smooth and free of paint.
Step 5
Prime the handlebars with a metal primer. Once the primer is dry, sand the handlebar until the primer fills only the low spots --- scratches and dents. Paint a second coat of primer on.
Step 6
Paint the handlebars with a paint designed to work with your primer. Three coats of paint provide a smooth and durable surface.
Step 7
Attach the handlebars to the bike. Add bike grips and all the accessories you originally stripped off.

Tips & Warnings

Wear safety glasses when cutting and grinding the metal.

Article Written By Bryan Hansel

Bryan Hansel is a freelance photographer and kayaking guide who began writing in 1993. His outdoors articles appear on various websites. Hansel holds a Bachelor of Arts in English and religion from the University of Iowa.

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