We have all been there. In the heat of battle one miss step or aggressive underestimate and wham... That ball end of your lever has departed. Now your left with a very scary spike o death.

Sure you could bring the two pieces to the welder but that's very 20th century. In the spirit of all of those wounded soldiers out there I have decided to go a different route.

First i had to go make a mold of a good lever bar end. Art supply stores have two part silicone easily available. I am using oom 30 from the local Blick art supply store.

Then take one of our fallen soldiers and grind a few anchor points into it.

Note the next ingredient in the back ground taken from my roll of carbon fiber.

Then add some epoxy resin from the local auto parts store and wala you have the worlds first prosthetic lever bar end.

Never forget your fallen soldiers!!!

Making my own full carbon levers too...

Please note that nothing i am making is for sale nor will it ever be. If you break a lever I highly suggest you go and buy a lever. I have arguably too much time on my hands with inspiration to push boundaries. People make a living off of creating things for your bike. I am not one of them. I do not endorse doing what I am doing to anybody. Support your local parts people!

--Biff

Good stuff Biff! A guy after my own heart!!!

I've been fabricating stuff since I took my dad's hacksaw to my LT125 Trail bike (circa 1973) and tried to turn it into a trials bike by cutting the head light off, for a start!

The most recent thing is the front sprocket guard in plastic on the Cota 4T... it split around the fastener hole.

Made a "shiny" one in thin stainless and popped it on.... voila! Never split again! Also shortened the side stand by 12mm and inserted a "nutcert" to fix lost stand rubber.

Imagine the cost of paying a 17 yr old, first year apprentice, in a dealership to do that work.

When I locate my camera I'll put a pic up!

I always thought if you own a motorcycle (any motorcycle) its your duty to work on them and know somewhat how they work.

Mags

Very cool Biff. When I bought my 4RT, the ball was broken off the clutch lever. I liked the length of the broken one but it felt like my finger might slip off the end. So I took some zinc rod and gas welded on a small ball. It took several tries but I got it eventually. It is fun to make your own stuff even if it take 4 hours to make a part that you can but for a few dollars.

they had to take the entire motor/gearbox unit completely out of the frame to clean the plug................

Now thats funny!!! Hehehehehehehe FujiGas and Dynamite didn't need it but they did!! Hehehe

Mags

Is there any manufacturers that make carbon fiber levers?

I am not sure. I remember that some manufacture had a carbon fiber wheel set. I made my own carbon fiber ty80 fenders and gas tank cap several years ago. That's in my garage section. I wouldn't suggest carbon fiber fenders for competition. I blew through a set on my old GG pro over the course of a national weekend.

--Biff