How to Make Chopper Bicycle Handlebars

Written by dustin covert
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Chopper bicycles are almost always a combination of bike parts scrapped from several different bicycles. Some bike companies design and sell bicycles of the chopper style, but recycling old parts to create a chopper style bike gives you a one-of-a-kind bicycle on a budget with lots of character. The handlebars on a chopper style bicycle are very distinctive; here is a rundown of how to salvage old bicycle handlebars and top off your chopper style bike.

Skill level:
Moderately Challenging

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Things you need

  • Old handlebars
  • Pipe bender
  • Sand paper
  • Paint

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  1. 1

    Find a pair of handlebars that will be suitable for modifying. You will need to look for handlebars that are extremely wide, with extra length that can be bent into shape. Many older '70s cruiser bikes made by Schwinn or of similar style have suitable handlebars.

  2. 2

    Remove handlebar grips or brake levers, a bell or anything else that is attached to the handlebars. Don't lose any screws or pieces that will be needed to reattach anything you want to put back on.

  3. 3

    Use the pipe bender to bend the handlebars upwards leaving flat space in between that can be reconnected to the bike. You can be creative with the shape of the handlebars, leaving them wider or bring them in closer together allowing for them to be higher.

  4. 4

    Sand the handlebars with sandpaper so they can be refinished. Older handlebars could have rust spots or areas where the finish has worn away and can deteriorate over time.

  5. 5

    Repaint your handlebars however you wish. A nice chrome finish is often used on chopper style bikes, but be creative and use a finish that fits the rest of your bike. Allow substantial time for the bike to dry.

  6. 6

    Attach the handlebars to your bike frame, if your bike frame does not already have the correct housing you may be able to salvage it from the bike you took your handlebars from.

  7. 7

    Reattach all handlebar grips, brake levers and anything else you will be using on your bicycle, (bells, lights, etc.) and ride off in style.

Tips and warnings

  • To get more shape out of your handlebars you can sever the bars at the middle and weld in extra piping of the correct size in the middle, this will allow you to get more height or width.

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