Bar End Diameter Adapter for Mountain Shifter on Drop Bars by fox_socks_

Last crawled date: 3 years ago

This is a bar end adapter I made so I could mount my Rohloff Shifter on drop bars without spending $100 on an adapter. It adapts a 23.8mm OD handlebar to have a 22.2mm OD portion at the end. It's possible to use this for other shifters, accessories, etc, but the size is designed and perfect for a Rohloff official shifter for the Speedhub 14.
I used a 1/4"-20 x 2-1/2" bolt and accompanying nut - usually prefer metric but I had a lot of these on hand. Any comparably sized bolt should also work. It should be obvious where these things go - nut in the expansion wedge and screw in the bar end. I recommend you assemble gently before installing in the bars.
I did my test prints with PLA, but did my final print with Nylon. Be sure to print the plug so the cylinder is standing up with the nut insert side up; be sure to print the bar end so it is laying down (rotate 90 degrees in your slicer). For the bar end, use support enforcers so the build plate side of the cylinder and the wedge cutout are supported. If you put supports everywhere, you'll have to drill out the screw hole. These orientations are critical for the strength of the part, ignoring this advice is likely to result in a bar end that easily shears off, and that would be bad - potentially very bad. I went with 100% infill which is probably overkill, but I wanted to be safe rather than sorry.
I provide these models for convenience but I take no responsibility at all, in any way whatsoever for anything that happens to you, your bicycle, or anything else as a result of you using this. There is absolutely zero warranty, express or implied. If you choose to use this on your bicycle or otherwise, you accept all risks associated with doing so.