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Our Process - Cyclone Handlebars

Posted by Jake Hindes on

We’ve been making our handlebars in-house, here in North Carolina, since day one. But, for years, every handlebar we sold was manually marked and bent using a heavily-modified JD2 bender. We used a handmade die and hydraulic bending setup which got us by, but over time we really started to push the limits of the rig. There was a lengthy time frame where we knew a full overhaul would be necessary to meet the demands and help us reach our manufacturing goals.

Well, thanks to you and your support throughout the years we have finally upgraded our worn out bender for an Ercolina numerical controlled bender which not only allows for much more consistency and frankly, higher quality products for you all, but also means that we’ll have many more handlebar options coming y'alls way soon!

Here's a little teaser on how we use the Ercolina numerical controlled bender to make our Cyclone Handlebars.

These handlebars came to fruition because we wanted to make buckhorn-inspired handlebar with classic styling, but with tighter radius bends and lots of pullback.

We start by measuring, then cutting stainless or mild 1” DOM .120 wall tubing to length, and de-burring the newly-cut edges.

Our Process - Cyclone Handlebars

Our Process - Cyclone Handlebars

Our Process - Cyclone Handlebars

Next, we put the steel on our lathe and sand the entire tube until we reach a clean, brushed finish.

Our Process - Cyclone Handlebars

Our Process - Cyclone Handlebars

After that (And many hours of initial trial and error), we’re ready to bend the tubing to the specs below:

  1. 5.5” clamping area 
  2. 5.5" clamping area
  3. 60° up at rise area
  4. 45° back & 30° down at grip area
  5. 6", 8" (select rise when added to cart)
  6. 8" grip area
  7. 5" of pull back
  8. 26" from end to end for the 6" rise
  9. 28" from end to end for the 8" rise 

 

Our Process - Cyclone Handlebars

Our Process - Cyclone Handlebars

Once the bending is complete, we give the bars a final wipe and hang them on the rack until they’re purchased. 

Our Process - Cyclone Handlebars

Have a project you'd like to use our Cyclone Handlebars for?

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