Replacement End Plug for Mountain Bike Handle Bars

thingiverse

The end plugs fell out of the handle bars on my mountain bike. I am using my bike for a triathlon this weekend and the race officials want all holes plugged so that the holes are not an additional hazard if there is a crash during the race. I took an existing SCAD file (http://www.thingiverse.com/thing:13301) and modified it as the basis of this plug. I printed 3/4" diameter plugs, but the SCAD file is parametric so you should be able to make any diameter plug. Instructions The plug consists of two parts; the actual plug and a spreader that is forced into the beveled back of the plug so that the plug is firmly clamped in the tube. I used a 25 mm M3 bolt and nut as the mechanism to draw the plug and spreader together ... probably overkill but it is a very tight fit! The nut fits into a slot in the back of the spreader ... I used a soldering iron to 'melt' the nut into the plastic of the spreader.