Bike Handlebar Alignment Tool

What?

A Bike handlebar alignment tool that doesn't require screwing or tools or lasers - just hook it on the handlebars and go! The tool aligns on the handlebars and rests on the headtube. Slots in the gauge are sized for a variety of tire width. Initial handlebar dia is 35mm, but I've since added a 31.8 adapter if need be. 

Why?

Sometimes on occasion you just can't get that handlebar aligned well with the front tire. This gauge lets you see the end of the tire, as well as the sides (depending on tire width).

Assembly

Slide the pins from the gauge piece into the main body (with bar hooks). Once the pins are slid in at 90deg, you can fold the tool to lock in place. The tool is self aligning. The folding mechanism was designed to allow it to be printed on a printer as small as the A1 Mini.

Function

The arrow at the front should be aligned in the middle of the tire (sometimes there’s a seam as shown) - at the same time you can eyeball the tire sides and if they’re parallel with the width gauge (below the arrow), you should be aligned. You can always eyeball your handlebar to fork crown or fork lowers (near the axle), as a double check. 

Once everything's aligned just push the tool forward and tighten the stem bolts to torque spec. Or if you have a long enough allen key you can tighten the bolts with the tool in place. In V2 I narrowed the hook width to better allow tightening in place.

Printing

Can be printed in one piece, but I recommend printing separately for pin and body strength (as shown in slicer image)

Printed in Prusament PLA Galaxy Black on a Prusa Core One 0.2 layer height, 15% infill, 4 walls, with normal supports (so they're inline and not on build plate) - in Bambu studio this is normal (auto) supports with Snug style. Can also do tree (auto), with hybrid style. Some of the overhangs you may need to paint. 

Step available upon request for a small cost. I put a lot of time into this one. Licensing is non-commercial so any external sales of this on other sites are prohibited. I can also print it for you but cost may vary depending on location. (I'm in USA)

If you think of some design improvements I'm happy to try and implement them. 

I printed V1 and V3

V1 vs V2

V2:

Added 31.8 Adapter (compatible w/ V1,V2,V3,V4)

Reworked geometry near bar to facilitate pushing it forward, but added a nub behind the bar for retention. 

Slimmed the model considerably

Added gauge stabilization bar to prevent snapping it like a twig and aid in printability.

V2 vs V3

Removed largest tire gauge to slim model further, aiding in printability once more. 

V3 vs V4

Exchanged radii for chamfers to aid printing. Changed frame holes to slots to reduce overhangs.

Notes

V4 released - see notes above!

V6 - an insane rework of the whole tool - coming soon. I'm working on putting this one as a new model in my creator space as it's taken quite a long time, with a ton of improvements. 

Updated Gauge!

Checkout the v6 foldable version here! Lots of improvements and a much more unique design.  The gauge piece (on the end with the big arrow and narrow lines) is compatible with the Alignment Tool, if you already printed this one. I find it easier to line up tires with the new gauge! It's easy to print just the gauge. See the link below. 

https://www.printables.com/model/1381113-bike-handlebar-alignment-tool-double-folding-v6-16

If you like my work, and have seen the Elegoo Centauri Carbon, consider checking it out with my affiliate link below. I purchased one with my own money, but I appreciate the support so I can keep making/reverse engineering cool models. 

https://elegoo.sjv.io/LKyzRo

Purchasing

If you don't have a 3D printer and would like to purchase this item, I would be happy to print and ship it to you. Send me a message at [email protected]. Located in USA but will ship globally if required. Shipping will vary and affect cost.