How to make an internal scooter bar

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Pete Pachota

Member
For anyone that cares:

An internal scooter bar is my original design. It's the cheap an effective way of making a one piece bar and to stop worrying about BREAKING YOUR FORKTUBE. It's simply impossible.

You need:

1 1" steel tube, as long as the length between the handlebars and the bottom of the forktube.
1 7/8" steel tube as long as you wish, as this will be the handlebar.
1 drill OR someone to drill for you
1 person who would weld it for you. Might be a grandpa/uncle/whoever, a car mechanic down the road, believe me, it's really EASY to find someone who will do a little welding job for you.
1 1/4" bolt with a nut
1 broken stock fork, one that's broken above the headset nut.
1 roll of duct tape

Firstly, take the tubes to the welder and have the wider one welded in the middle of the thinner one. Then shove the bars into the fork. Check if it fits really tight. If not, take it out, duct tape the bottom and check again. Repeat the process until it fits tight. Next, set the bars straight and drill/have someone drill a 1/4" hole right below the bottom headset bearing, through the fork and the bottom of your bar. Put the bolt through the hole, screw it tight and you're done.

CAUTION: Some new a forks have smaller ID, you might check if an intenal bar will fit simply by trying to shove a stock T tube into the fork to see if it fits.
 
Madis

Madis

Super Geek
Staff member
Added to super-modding thread.
Some extra pictures would come useful, i hope you have some :)
 
P

Pete Pachota

Member
Bobby Fishwick said:
Niceee ... sounds like a flawless design
Click to expand...
The only flaw is that the bar bends after some time, mine is bent like half an inch at the top, and that's after riding it for more than half a year. It's not bent as it's going to snap at the bottom, the tube is curved. They're perfectly ridable though, and after all, bending like that is the most peaceful way of wearing out a part, haha.

Basically, this is directed to people who won't bother getting some of the better bars on the market because of various reasons, and for those suffering from fork problems. After all, there's still plenty of people riding stock bars with custom crossbars.
 
J

jeff26

Member
well you should have posted it up any way or asked someone about it. Pete posted it so pete gets credit. if its not in the super modding thread it probably hasnt been done or its a bad idea.
 
S

Snow Patrol

Member
its been done bofore by other sports with similar forks, so its not really original.

but you are probably one of the first to do it to a scooter.
 
P

Pete Pachota

Member
John Radtke said:
its been done bofore by other sports with similar forks, so its not really original.

but you are probably one of the first to do it to a scooter.
Click to expand...
My friend has a bike which is pretty much like that, except it has a clamp on the fork right above the top headset instead of the bolt. I wasn't influenced by it, first, I wanted to make a custom T tube, then someone suggested to get rid of the stem, and I thought Id rather bolt it. So yeah, this might not be 'my original idea', I haven't heard of anyone else riding such bars though.
 
Madis

Madis

Super Geek
Staff member
Pete Pachota said:
John Radtke said:
its been done bofore by other sports with similar forks, so its not really original.

but you are probably one of the first to do it to a scooter.
Click to expand...
My friend has a bike which is pretty much like that, except it has a clamp on the fork right above the top headset instead of the bolt. I wasn't influenced by it, first, I wanted to make a custom T tube, then someone suggested to get rid of the stem, and I thought Id rather bolt it. So yeah, this might not be 'my original idea', I haven't heard of anyone else riding such bars though.
Click to expand...
Was me, because i thought that holding that steertube on your fork just adds weight since the bar itself is already attached to the fork internally. Although i had no idea about that internal bar if it's really fit in the forktube so it won't wobble. Are you planning to get a 1-inch OD tube soon to replace the 25mm one?
 
P

Pete Pachota

Member
Madis said:
Pete Pachota said:
John Radtke said:
its been done bofore by other sports with similar forks, so its not really original.

but you are probably one of the first to do it to a scooter.
Click to expand...
My friend has a bike which is pretty much like that, except it has a clamp on the fork right above the top headset instead of the bolt. I wasn't influenced by it, first, I wanted to make a custom T tube, then someone suggested to get rid of the stem, and I thought Id rather bolt it. So yeah, this might not be 'my original idea', I haven't heard of anyone else riding such bars though.
Click to expand...
Was me, because i thought that holding that steertube on your fork just adds weight since the bar itself is already attached to the fork internally. Although i had no idea about that internal bar if it's really fit in the forktube so it won't wobble. Are you planning to get a 1-inch OD tube soon to replace the 25mm one?
Click to expand...
Nah, Ive messed up with the previous post, someone suggested to weld the bar to the fork, and then I thought that it would be better to bolt it. My first bar was bolted to the stem like what you should do with a stock T tube to get rid of the clamp.

And no, it's just fine with the duct tape.
 
0

04joel

Member
if i make new handel bars with a 30mm t-tube base for my new a, will i need a double clamp, oversized clamp or both

cheers
 
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