The picture story contains descriptions and thoughts during the build process of the second generation maegic [mˈæd͡ʒɪk] caet [kˈæt] handlebars. A story twist is also included. The monkey bars are one of my favorite handlebars back in the days. I used left over tubes to build two of them for future builds. I think I'm addicted to BMX handlebars.
Here I share my honest results on how to make BMX parts at home. For a professional, I think it's completely different. Please always remember that I am not a professional welder. Nothing perfect but not too bad either.
enjoy the slide show or click the pics to see them in full screen ...
It all started with raw tubes. Taking the drawings of caet gen 1 i planned to reduce the overstays to make them more elegant.
Cutted the tubes to the length with reduced overstays and angled ends.
Back to the drawings to check the dimensions.
Confirmed dimensions provisionally.
Drilling the angled holes using the same angle as for the tube ends.
I used a tube notcher / tube miter to drill the holes - maintaining the correct angle.
First fit check on the gras.
Examining the gap dimensions.
You can see the different wall thickness of the tubes. Makes them stronger in clamp- and grip area but heavier than the 1st gen caet bars.
Examining the gap dimensions.
Cleaning up the tubes and bend the handle ends.
Preparing for the next steps.
Close tube ends and grind them cleanly.
Next fit check with closed tubes.
Checking the gap dimensions again.
Because i don't like the wide look any more, i decided to make them smaller more like the monkey bars.
Cutted down the clamp area and closed the ends again.
Fit check number three and taken the first weight. Second gen are heavier than first gen, because of thicker tubes in clamp- and grip area.
After alignment of the tubes they have been tagged.
Let the tube rest and cool down before starting new welds.
Yeah, 2nd gen caet bars looking more elegant with smaller dimension and reduced tube overstays.
