Talaria Komodo - Handlebar Bar Ends with Expanding Bar Inserts

Unlike setups that require you to retain heavy OEM mirror mounting hardware, this design includes a fully 3D-printable expanding internal wedge system. When you tighten the central bolt, the internal sleeve expands inside the handlebar bore, locking the bar end rock-solid in place. Perfect for eliminating bulky stock mirrors, shielding your throttle tube in crashes, and giving your cockpit a clean, minimalist factory look.

Key Features:

• Complete Standalone Setup: Includes both the outer protective cap and the matching expanding inner wedge. No stock mirror hardware required.

• Crash & Grip Protection: Prevents the handlebar ends from digging into the dirt, keeping debris out of the throttle mechanism during drops.

• Universal Fitment: Engineered specifically for standard handlebars used on the Talaria Komodo.

Hardware Required (BOM):

• 2x M5 (or M6) countersunk or socket cap bolts (length depends on the cap depth, typically 40–50 mm).

• 2x M5 (or M6) standard nuts to draw the expanding wedge.

Recommended Print Settings:

• Material:

  • Internal Expanding Wedge/Sleeve: Use a stiff, rigid filament like PETG, ASA, or Polycarbonate (PC). The wedge must not deform or compress permanently when tightened. Avoid soft TPU or standard PLA for the wedge.

  • Outer Bar Cap: You can print the outer slider in rigid ASA/PC for a smooth slider feel, or in a firm flexible filament like TPU 95A / TPE for maximum impact damping and scratch resistance.

• Wall/Perimeters: 5 to 6 perimeters minimum on both parts to handle bolt clamping force.

• Infill: 50% to 100% infill for high density and crush resistance.

• Orientation:

  • Print the outer cap flat on its face (clean finish, strong bolt seat).

  • Print the wedge vertically or horizontally according to the split-line design so the expanding slots don't fuse.

• Supports: Usually none required if oriented flat.