This instructable describes how to make a unique handlebar/stem combo using carbon fiber and aluminium. The design allows seamless integration of LEDs and batteries.
A milling machine is needed for the stem and composite lay-up supplies for the handlebar. A 2,5 axis NC-milling machine and vacuum bagging system is recommended. We made use of laser cutting, water-jet cutting and 3D printing, but they can be replaced with manual cutting and sculpting.
The handlebar consists of a sandwich structure with two identical curved skins or faces, two mirrored corrugated cores and two mirrored tubular handles. The stem consists of a main body, clamp and face plate. The design shown here has two rearward facing 3x3 red LEDs, one 4x4 white LED array facing forward and a push button switch with a blue background LED. The system is powered by four CR2032 button batteries. The whole package is very light and has excellent torsional stiffness even-though it is not a tubular structure.
Updates etc. will be up on the project's website later this year http://www.ideas2cycles.com