Sizing & Cutting Handlebars | Tech Tuesday

Are you having second thoughts about your super-wide flat bars? Maybe we can help. Calvin and Truman look at a few ways to determine ideal bar width, and go through the cutting process on aluminum and carbon handlebars.
Questions or comments? Leave them below!
Get a more in-depth look at flat bar brake lever mounting & positioning ▶︎
• Brake Lever Mounting &...
➤ Tools & materials used:
• RR-12 Tape Measure - www.parktool.com/product/tape...
• HBH-2 Handlebar Holder - www.parktool.com/product/hand...
• AWS-1 3-Way Hex Wrench - www.parktool.com/product/3-wa...
• SAW-1 Hacksaw - www.parktool.com/product/hack...
• SG-7.2 Oversized Adjustable Saw Guide - www.parktool.com/product/over...
• DC-1 Digital Caliper - www.parktool.com/product/digi...
• CSB-1 Carbon Cutting Saw Blade - www.parktool.com/product/carb...
➤ Fix It:
Did you know that Park Tool is the #1 resource for bicycle repair education?
• Visit our KZbin Channel: / parktool
• Visit the Repair Help section of Parktool.com: www.parktool.com/blog/repair-h...
• Check out The Big Blue Book of Bicycle Repair: www.parktool.com/product/big-b...
➤ About Park Tool:
Since our founding in 1963, Park Tool has been the leading name in bicycle tools. Our KZbin channel is an extension of our mission to be the ultimate resource for mechanics and riders of all skill levels. Here you will find comprehensive repair help tutorials for a wide range of components and processes, as well as troubleshooting guides, tips and tricks, and information on the latest Park Tool products.
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[@bigarnd]

Park tool branded machete... I would buy that...

[@ThinkyPain]

Park MCT-1

[@bigarnd]

Thinky Pain yes!

[@th_js]

Oh yess

[@jackbeames7643]

Tomi Saaranen hello. Aha.

[@bensblues]

Wouldn't be surprised if they made one

[@huybanh3825]

Rumour has it, three cameramen were jabbed in the eye by Calvin's machete in the opening scene.

[@qweam229]

Honestly for the amount of effort they put into their videos they should have more veiws and subscribers

[@VideoNOLA]

Pro tip: Wadded up damp cloth on a string, shoved into the handlebar end before cutting begins, helps pull out any lingering shavings without much hassle or sending dust airborne.

[@tobiasl-d7331]

Before you buy the handlebars, run around the bike shop pretending to ride a rock garden

[@parktool]

That is actually an interesting idea.

[@richarde1355]

Or, at the shop, while holding the bars drop down to do push-ups and check the fit!

[@AF-O6]

This is a great company that stands behind its products. I’m a customer for life based on how they treated me for a minor problem. The videos are sometime corny, but love the products!!!

[@satchmotionrc8202]

A good old-fashioned shop vacuum will also work for cleaning out that mm of fragments. Loving the tutorials!

[@Durwood71]

I realized after I started to develop pain in my shoulders that my bars at 29" were way too wide for me. So I determined the optimal width using the "zen" method: I straddled my bike, closed my eyes, held my arms comfortably in front of me, and then let my hands drop naturally onto the bars, which landed them about two inches from the end on each side, so I cut off 1.5 inches using a pipe cutter, and even after just a few minutes of test riding, I could already feel my shoulders relaxing. In theory, I'm sacrificing stability, but I think my shoulders will be happier in the long run.

[@monkeyking847]

Hey Calvin, recently started working at a bike shop, one of the mechanics there who is just a genius of bike maintenance and repair was telling me he studied under you at a bicycle institute after I mentioned I love watching your videos, which I thought was so cool! Keep up the awesome work.

[@luispiros]

I try not to subscribe to commercial accounts but Park Tool has the most respectful advertisements to it’s viewership. Honest and ethical.

[@tlf.]

This is just a useful tool commercial I love it

[@benjaminvg8018]

Love the cheesy acting 😂

[@retrodog63]

It wasn't meant to be. Doh!!!

[@remotecontrolcentral4928]

R/whooosh

[@onlyonecannoli3952]

Glad that you and the rest of the five year olds enjoyed it.

[@benjaminvg8018]

@@onlyonecannoli3952 Someone is angry 😡

[@onlyonecannoli3952]

@@benjaminvg8018 Not really. Just puzzled at how someone can be so dimwitted as to like this video. But hey, there are no laws against it, so have at it.

[@cjrazzle]

Great vid fellas. It's not a bad idea to start your cut on aluminum bars with a pipe cutter because it will give you the cleanest line around the bar. Finish the cut with a finer tooth hacksaw blade that will naturally follow the shallow cut from there and you have a job well done with very common and inexpensive multi-purpose tools.

[@NelsonTrujillo1]

Was having a so-so day and these guys made my day. And... just realized my handlebars are wider than needed, this video will help me do it very soon. Thanks for the video

[@sethfrankel3542]

Technically, you can’t use calipers to directly measure the thickness of the cut a blade will make. It’s called the kerf thickness and you need to make a sample cut to determine the thickness or know the offset of the teeth dimenion. Teeth are always slightly offset to the alternating sides of the blade to intentionally make a wider cut than the thickness of the blade so that the blade does not bind in the material being cut. Ok, fine, we’re talking a negligible amount, and these are bike mechanics anyway, not precision machinists! Also, if you make with an ultra-fine sharpie the position of the shifter/brake clamp before loosening then you can reference that and never have to guess at the angle later. Thanks, gentlemen.

[@123456bmx]

The 14 people who disliked cut with metal hacksaw blades in both directions

[@obi-wankenobi9871]

Doesnt matter when you do that, especially not with aluminium.

[@ratsac]

I’ve recently had two bar strikes on trees at speed, which resulted in some lovely bruises on my thighs (both legs). After watching this, my bars seem almost 100mm too wide for me! Definitely going to cut some off. Thanks guys! Oh and alloy bars are relatively cheap if you cut too much off.

[@DrDrew1979]

I really liked the new more lively and humorous approach. Not sure why other commenters disliked it. Maybe cheesy, so what? Still funny! I prefer new style over the old "cold bare details" style

[@parktool]

Third.........Missing that hair.... eh, maybe not.

[@matejmanceta1794]

No coments on Park tool coment? Not in my watch!

[@richarde1355]

Calvin and Truman, you two are awesome! Thank you so much for this video!

[@jerrygundecker743]

I did pretty much what you did before I saw this video. I wrapped electrical tape on the bar, (Alum), (making sure my shift and brake levers fit comfortably), and cut along the tape freehand. I then took the cutoff and used it for a measure, applied the tape to the other end of the bar, and cut at the end of the electr. tape, as straight as I could. Deburred it. Worked out fine. A millimeter or two makes no diff. when the grips or tape are back on. Good luck.

[@dirtycommtroop]

I just took the 780mm bars on my new bike down to 730mm which is a bit wider than my last bike. This video made me feel much better about my decision.

[@darkriverracing22]

After cutting down carbon bars, I like to apply a small amount of c.a. to the surface of the cut to seal the carbon. Just a nice finishing touch.

[@NealHartsChannel]

These videos are so good. The way they teach is awesome!

[@beardsleymcbearderton6492]

Calvin, you guys rock! love these videos!

[@ericpatterson8596]

Great video and great job parktools !! 👍👍

[@simeone74]

just brilliant - great job, guys

[@larryrobinson7037]

Love all these videos - especially to help us get through the pandemic. All the corny comments and stunts are great too.

[@saulsandoval2313]

All good tips. Thank you👍

[@ed0078]

Excellent tutorial

[@th_js]

Awesome video guys, like always!! I rarely watch these for actual repair help, but entertainment, because these are just soo good!! 👍🏻

[@matejmanceta1794]

Again

[@aninesyik6555]

Awesome instruction! Thank you!

[@Bad.Rabbit]

I had 780 bars. I'd wait till I was in a good groove and comfortable, then look at my hand position. I was running on the inside of the grip more, so I cut 10mm off each end. Now I ride almost at the end of the grip. Perfect at 760

[@rhuynh]

How tall are you and does your wing span matcj?

[@mattjustin3596]

You guys' videos are the best.

[@abusedpigeons225]

My favorite position for my cockpit levers is where ever Walmart puts them

[@grindeyyyyy]

Legend has it you ride Walmart bikes in shop condition because you love the danger

[@biggaywizard]

I really appreciate your info, the carbon cutting was the most helpful. It seems to me that bar width is still just up to your personal preference. On a side note, for holding the bars in place I use two old toe straps between the front wheel and down tube, I find the have a more of a firm grip on holding the bars in place.

[@zbynekcodykolacek]

Really great fun and tech.

[@diokipadaca8796]

I usually shape the sandpaper/emery cloth into small cones. One with the grit inside and one outside. Then I use these to debur the inside and outside diameter by turning it around the sharp edges. I get better roundness this way.

[@giuliom8520]

Very comprehensive video! Great job! You guys must be instructors because you guys seem like experts.

[@juluisreyes9094]

The push up position method works for me guys as i have quite long reach..nice one guys

[@SD-nq6kg]

Park Tool The Gold Standard

[@Daniel_D_King]

I found a video a while ago, recommended multiplying your height in cm by 4.40 to give bar length in mm as your maximum. Go less if you like but not more. To wide will move the work from the muscle groups in shoulders and back up to just the shoulders and cause damage. Iv found this to be perfect for me. Im 165cm x 4.4 = 726mm bars. I run 720mm comfortably.

[@parktool]

Interesting.

[@energ8t]

You should definitely be wearing a dust mask for the carbon. 20 years from now, you’ll be glad you did. My dad and my grandfather both died from asbestos exposure; mesothelioma.

[@Kegel_Destroyer]

Dude with the stash reminds me of the random guy at the pub that really wants to talk, but you dont want to.

[@mymorristribe]

hmm, I cut my carbon fiber bar with a jig saw. Took about 1 min to measure and cut each side. It's interesting to see the OCD version of what I did.

[@rupedog]

Carbon dust is exceptionally toxic. Hope u wore a min p2 mask or damped down at least. Ideally both. Jigsaw would defo send fine dust (fairly invisible to eye) into air

[@kennyc1101]

I’ve this tool by Park Tool but I find that using my Ridgid plumber pipe tubing cutter a lot faster. Just spin a few round and job done

[@ratoneJR]

did push ups and measured hand spacing. 700 mm bars measured right and work great

[@Chris-de2qc]

Handlebar baby!

[@calebbrown6858]

Great vid, as usu, fellas!

[@denishuber7758]

I like the brake lever angle about 30° and away from the handlebars about 20mm....given a bit more leverage

[@x-1584]

I won't piss Calvin off.

[@zygmuntthecacaokakistocrat6589]

When cutting, stand in front, and stabilize with your free hand on this side (ambidexterity is useful here!). Reverse for the other side, and/or grip the front wheel with your knees. BTW, those slots in the guide are called 'kerf guides'. With carbon bar shortening, rotate the guide 90º halfway through the cut to avoid torn fibres at the end of the cut. Also, it's better to use a vacuum cleaner to suck up carbon dust. Get someone to hold the hose nearby whilst the cut's being made.

[@yani1343]

It might sound weird but I like my shift and brake levers vertical

[@Mr_RichardH]

Calvin waving a machete around is terrifying.

[@inigopatten3413]

i like my brake and shift levers on the handlebars.

[@scottlohr4126]

I have shoulder issues, and have been finding a wider bar is fine, generally, but pulling up and back on the bar and turning at speed is a problem (think of a shoulder working like indexed shifting). I got back to a much more natural lean-turn, and can wheelie easier in my 620. Plus I find the longer stem length adds to stability more than bar width (again, more at speed). Sure did feel weird initially!

[@mr.wizeguy8995]

I used angle grinder and it took like 10 seconds to cut both ends doesn't matter if you cut slight off handlebar grip is going to hide cut end anyway. If you use some end cap then it needs to be 90 degree cut and this method would be better.

[@KVandendriessche]

Hahahaha you guys are awesome! Thanks for the laugh

[@lienquanmobile7994]

This episode should be on Comedy Central.

[@RNicknackpaddywhack]

Most of his knowledge and authority comes from his majestic mustache.

[@richarde1355]

I like my brakes and shifters positioned like Truman described. I guess my hands are kinda wide-ish, and the webbing of my hand will bands into the shifter if it isn’t positioned a little more onboard than his Calvin describes.

[@chrisgates3128]

My method is make them ab 3-4 inches away from front of seat so u dont hit knees when u bar spin

[@grindeyyyyy]

I need one of them saw guides, cut bars and steer tube down yesterday, not a straight cut, I ride my bars at around 550 to 600 (track bike)

[@that70sschwinn]

Always good to cut one first...

[@josereneducharme142]

Please tell me no handlebar has been hurt during the production of this film.

[@fifthcircle1]

Shifters on the down tube, and a coaster brake.

[@2creativo11]

Corney but very informative. Park is my go-to DIY bike spot. Thanks

[@andrewmaljaars2693]

Do you have a similar video for choosing the best stem length?

[@ub3227]

I like my shifters and brakes where they are easy to reach by just extending my fingers but don’t bother me when I’m just holding onto the handlebars.

[@theoretically3130]

This made me laugh so hard

[@kristenwarren1780]

How did the "feeling" test compare to the push up test? (In terms of bar width measurement.) thanks!

[@axelbuckets3858]

Like for the new handlebar babies

[@darius2640]

My technique is to mind you current setup and then try all your buddies bikes choose your favourite and ask for specs

[@chineseobelisk]

I put the handlebar in a vise and use a plumbing deburring tool.

[@caRpetbomBer1]

The machete would make a great hipster handlebar.

[@NonLegitNation2]

I was on the 780mm bandwagon for a while, but was getting tired of having to turn my wheel sideways to get into doorways since i store my bike inside. I went to 760mm and although it's only 40mm shorter they feel better and it's a little easier to get into doorways.

[@parktool]

Nice. Make the bikes fit into your life.

[@PeterZeller1]

Me at the end of the video: I don't even want shorter handlebars, why did I watch this?

[@alexnicolaou3579]

am I strange for prefering the shifter mount on the outside of the brake mount, a bit closer to the grips? i just love it when the shift levers are exactly below the grips and the brake lever further away, allowing for intuitive one finger braking. of course i place my hands right at the edge of the grips and sometimes even put my palms on the bar end plugs as an alternative position on long rides. the outside placement of the shifters allows for an easy finger to shifter reach even when holding like that

[@parktool]

There is no strange in comfort. Whatever works for you is great.

[@alexnicolaou3579]

Thanx ParkTool, i was always feeling "different" for setting up my cockpit in that 'unusual' way, unlike the rest of the setups i see. Haven't tried iSpec or simmilar integrated clamp yet though..

[@MayorofNilbog]

That's a gorgeous bike. Currently near impossible to find with the bike shortage.

[@robertmcfadyen9156]

I have my own bicycles and have no appetite for new ones no matter how good they might look . I would not forget the day when a cop defamed me in front of a bicycle shop owner unwittingly many years ago . I was so embarrassed .

[@sumnerbob2254]

Truman!

[@robertmcfadyen9156]

I have a pipe deburring tool for the ends of tubing .

[@minysmith9043]

Marketing came in thick at the sg72...lol....I'll stick with my tube cutter from the hardware store. Accurate cuts and no ducking around....sure that tapes measuring 20mm too lol all bent up. Park, I know it's just bikes, but calipers? A ruler?

[@konstakasonen7332]

3,16 use your grips (only if they have metal ends) they are also level and stuff

[@rupedog]

Or use an.old grip, cut the end off, turn around/put on backwArds...instant guide

[@the_blair_bike_project]

I think Calvin should star in the next Machete movie alongside Danny Trejo.

[@danhenderson783]

I'm going to buy a saw guide so I can use it once every 4-5 years. Okie Doke

[@HackedUpForBarbeque]

My thoughts exactly. Plus if you have lockons you already have a saw guide. Just use the two locking rings.

[@mariamartins367]

Just sawed my bar yesterday. Had nothing better to do. Unavoidably the cut was not straight. Wish i had the tool, can’t see any diy for that. But it’s a lame tool to have when it’s a one off.

[@iwontreplybacklol7481]

$45 tool at that 😂😂😂😂 I use a dremel with a cut off wheel, much more useful for lots of other things.whuch is a better value.

[@aldrinclementina4297]

Hi there.. I had 580mm bars on my "26, but I'm widen it a little bit. I have a 750mm on it just to try otherwise I will trim it down to maybe 740mm or 680mm. One other thing. I don't know at what degrees but I like my brake levers at a level/ angle that my natural hand movement can get to it. I know this is an old video and I hope you guys read this comment. What do you guys think of my 26' XC bike with 75mm stem and 750mm bars. What do you guys recommend me? Thanks for sharing

[@troym1849]

Those expensive tools so not necessary. Hack saw, bandsaw, dremels work great.

[@spicydeath82]

an actual hand deburrer tool works great for this application too.

[@geemail369]

How did the 700mm (push up position) contribute to the final cut?!

[@arepea6087]

Pipe cutter, pipe cutter! So much cleaner.

[@MichaelMolli]

The test ride at the end is missing.

[@swpa8742]

I like long bars because I can hook them around a tree at the top of a steep hill and take a break without taking my feet off the pedals lol.

[@sean0611]

Did he just cut one side?!

[@vuelvoel2011]

yes

[@sean0611]

capitan futuro wait really? Arent you supposed to cut both so its even?

[@vuelvoel2011]

Sean hahaha you must cut both sides

[@sean0611]

capitan futuro i knew it lol i tjought u only cut one

[@Chris-de2qc]

Better safe than sorry

[@user-qw2tt6su7p]

I personally like my handlebars exactly 7886mm wide. I think I am going to get wider bars though

[@YavorM-Yash]

And that's nearly 8 meters wide, you know...

[@user-qw2tt6su7p]

Явор Марков Yes it gives me lots of control

[@truantray]

jason scheffel Its the evolution of cycling. My 2025 bike will have 9 meter bars and 1x 65 speeds, 49er inch wheels, and 12 suspension components I will lock out at all times.

[@user-qw2tt6su7p]

okleydokley will your suspension be made by rockshox, fox, or apple. With Siri built in

[@avaf7699]

First u got X0 Carbon then a bike with RSC... nice

[@DanGadd]

Ive never cut down any of my bars, 800mm is perfect for me

[@storz100mm]

So which way do the teeth point on the saw blade. Towards the saw handle or away from it?

[@parktool]

Away from the handle. Cut on the push, not on the pull.

[@user-pe1qz3rt3f]

Iike to use chain saw

[@rinky_dinky]

i gots to know what flat bars are those on the Salsa bike ! is it the salt flat delux ?

[@parktool]

Thats correct!

[@hael8680]

What is the best way of removing and reinstalling the grips?

[@parktool]

I prefer air to put on grips. kzbin.info/www/bejne/en-Vgmuqo7R_pdE

[@dereine385]

Lift the inner Edge with your finger,Spray some Brake-cleaner or alcohol in the inside and pull it Off.