Picture of Customized handlebars with Sugru
During a recent bike fit I had complained that my existing handlebars didn't seem to have a sweet-spot behind the brake hoods. The curve of the handlebars, as they started to sweep forward, dipped downward. Tipping the handlebars up wasn't an option, if I wanted to be able to use the drops. So I had two options:
1) Buy a new handlebar (not in my budget right now)
2) Build up a "sweet-spot" on my existing handlebars.

I decided on option #2 after seeing a few Instructables that used a product called Sugru - quote from their website "sugru is the new self-setting rubber for fixing, modifying and improving your stuff."

So I decided to give it a try.
Remove these adsRemove these ads by Signing Up

Step 1: Materials

Picture of Materials
Here's what you're going to need:

1 - Bicycle requiring handlebar customization - mine was a Specialized Tarmac road bike with Forte carbon fiber hardlebars
2 - Sugru - I needed Qty 2 - 0.7oz packets
3 - latex gloves - may not be needed, depends on if you think you may be sensitive to the Sugru
4 - scissors
5 - Handlebar Tape (optional - depends on the condition of your existing tape)

Step 2: Getting Started

Picture of Getting Started
To begin, unwrap the handlebar tape from the area (sweet spot) where the Sugru will be applied. At first I thought I would try reusing the handlebar tape, but that didn't work out because it was somewhat worn and stretched.  So, if you plan to do something similar, be sure to have a package of new handlebar tape on hand. The photos in this step show both the right and left side of the handlebar, with the handlebar tape removed.
This is genius !!!! LOVE it, super clever, will be trying this soon. Thank you for sharing
MordechajM2 months ago

That's a strange positioning of brake levers on bars.

Great instructable! And (I know this is dating me), I watched Fireball XL5 during its first US run, so you get extra points for the nick!
fireballxl5 (author)  TheOlMaestro2 years ago
Thanks and I too can remember Fireball XL5 from the first US run, "I wish I were a spaceman the fastest guy alive".
fireballxl5 (author) 2 years ago
I just wanted to say thanks to the Instructables team for the great site for sharing these DIY projects and for the visibility for this project.
Hewer2 years ago
Great idea- I've got the same hand position issue on my road bike. I haven't worked with Sugru before, so the answer may be obvious- would applying the Sugru the way you have make it difficult to change the brake cables? I guess, would it come off easily, or would you have to cut it off and re-apply fresh?

fireballxl5 (author)  Hewer2 years ago
Good question, I'll pose this to the Sugru people to be sure, but as I understand it, it should just peel off, possibly leaving some residual rubber. If that were the case, then it wouldn't be a problem on a alloy type handlebar, but with CF, you'd want to use something like a plastic putty knife, if there were a lot to remove. The resulting cured Sugru rubber is soft enough, that you should be able to free up the cable housing, if necessary, without disturbing the rest of it. Also, if the Sugru "fill" piece would come off intact, it could just be re-secured with a thin layer of Sugru to "glue" it back into place.