How to Make Chopper Bicycle Handlebars

How to Make Chopper Bicycle Handlebars
A chopper bicycle is a low-riding bike with an extended front fork. The low height of the bike and the steep angle produced by an extended fork requires a longer handlebar than a typical road or mountain bike. Because BMX handlebars are long, they are easily modified to make chopper bicycle handlebars. Modifying any original part of a bike into a custom part captures the spirit of the term chopper, so a modified BMX handlebar on a chopper looks good, too.


Difficulty: Moderate

Things You’ll Need:
  • BMX handlebars
  • Saw
  • Grinder
  • Paint thinner
  • Sandpaper
  • Primer
  • Paint
Step 1
Take the grips and brakes off of a BMX handlebar. Remove it from the bike.
Step 2
Use a hacksaw to remove the crossbar - the bar that runs between the grips and holds the bar pad - from the BMX handlebars. Cutting close to the main handlebars will minimize grinding. With the removal of the crossbar, the BMX handlebar becomes a chopper bicycle handlebar.
Step 3
Smooth the sharp edges from the crossbar cut. Use a grinder to smooth all the burrs and the original welds from the remaining handlebar tubes. Smooth the bars, but make sure not to cut into the handlebar tubes. Grinding into the tubes weakens the handlebar.
Step 4
Use paint thinner and sandpaper to remove the original paint.
Step 5
Paint the handles with a primer. Use two coats and sand between coats. The goal is to have the primer fill the imperfections on the handlebar. This creates a smooth surface for the paint.
Step 6
Paint the handlebars with three coats of paint for an even and tough finish. Sand between coats. Make sure the paint you use is compatible with the primer you used.
Step 7
Install the modified handlebars onto your chopper. Replace the grips and brakes as desired.

Tips & Warnings

Wear safety glasses when grinding.

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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