Bike Handlebar Mount

Overview

To provide a stable platform for mounting a bike headlight and an action camera to my bike, I wanted to build a very sturdy mount that could clamp to either side of where the stem connects to the handlebar.

This is my end product:

Material and Equipment

• • 1" aluminum square stock

  • Stainless steel screens

  • 1 1/4" endmill (matches diameter of my handlebars)

Steps

• 1. First, I cut two equal length pieces of aluminum stock.

  2. I mounted these into the vice with a little over 1/2" exposed up top.

• 1. I milled off 1/2" of material, leaving a 1/4" tab at the left side on one piece, which is the mounting surface for the lights/camera.

• 1. For comparison, here are the 2 pieces below a completed mount:

• 1. I used the 1 1/4" end mill to bore out the curves for the handlebar. I offset it 0.1" so that there is a gap between the two pieces when they fit together over the handlebar -- this gives space to actually clamp down.

  2. I drilled and tapped the smaller piece to accept #6-32 screws.

• 1. The finished product is seem at the top of the page!