The RedLine Deep V Handlebar
Always looking for ways to improve a product, my dad set his sights on the BMX handlebar in the mid 1970s. BMXers were were pretty hard on everything before realizing that smoother is better, and bars were among the items regularly cracked or broken. Since much of the time it happened at the crossbar weld joint, he figured he'd give that area somewhere to go when overstressed. A straight bar is not going to stretch, but the V bar can flex, essentially lengthening as it does. Plus, it looked super cool. It still looks super cool. Scroll to see how I re-created the classic "Deep V-Bar"!
Cut to Length and Prep
First order of business with most parts is to cut the material to a length close to finish dimension, but with room. I could cut handlebar tubes right to length, but with this batch, I performed all four bends to each bar in succession, which means I'm starting from one end instead of the middle. So, If I'm even a tiny bit off on the tangent point of the first bend, I could run out of material on the other end. Not good! So, I left a little cushion and trimmed to overall width at the end. Next, I push a piece of rag through with some solvent to be sure nothing is inside the tube. The mandrel is a pretty close fit and even the smallest metal chip could cause the tube to slip or even break during the bend cycle.
Bending
The coolest thing about this operation is that I'm using the bender that my dad used to make the first V-Bars 50 years ago. Not just one like it, the EXACT machine! I have the invoice with his signature and the serial number matches. When I stand at this machine, it's a very surreal experience. As I mentioned, I start at one end and a finished piece comes off the machine when done. So, all settings for each bend have to be perfect and every setting is done mechanically. Point of bend, plane of bend and degree of bend. If it slips in the collet just a tiny bit, the part is probably scrap. It takes some set up and a close watch, but this machine is half a century old and still kicks ass. I can't imagine machines of today being used in 2075. With this one, I can trace what needs fixing and fix it. Plus, these pieces I'm creating need to be made with every bit of authenticity I can put into them. This is how I do it.
Crossbar and mitering
The bending of the crossbar is not too difficult, but there are still pitfalls. First, the radius chosen by my dad way back when is as tight as can be reliably done with a basic plug Mandrel, which I know was used, so I use one, too. Then, although a slight difference in degree of bend would never be visually perceptible, it would create a problem when mitering the ends. A straight tube is simple. Miter one end of all the tubes and then use a stop with a clocking feature to miter the other. The "V" introduces complications, but it ain't rocket science. After the mitering is done, I de-burr inside and out to be sure that no little chunks get stuck inside after welding and rattle. But, before welding, I also have to get the grease used for the mandrel out of the tube. Manufacturers of large quantities have specialty methods for that, but I use a simple method that works for me.
SERIOUS mojo here!
These early V-Bar Re-creations are at the top of the food chain when it comes to built in RedLine DNA. If using the original bender isn't enough, the contraption you see in the picture is the original air actuated fixture for tacking the crossbar in place. It was made by Mike Konle 50 years ago and was in rough looking shape, but as with all old tools, it just needed disassembly, a wire wheel, steel wool, wax and grease. The air ram and foot control were easy to get back into shape, too. I'm even using the original air hoses. Works like a champ and packs even more authenticity into these things. So freaking cool!
My Favorite Part!
Sometimes I wish I could weld all day. I didn't feel that way when I used to do just that. But, even then, I truly enjoyed the artistry of it. More so now, actually. Tig welding is not easy and I wasn't at all a natural. Plus, I learned to TIG weld before learning any other style. That's usually not how it's done, but my dad was a great TIG welder, so that's what we did. I practiced a lot. I was a better aluminum welder than steel back then, but I think I evened out. To be a truly great TIG welder who is also fast, you have to do it consistently. Back in the day, I could weld in any position, move quickly and it just looked good! Now, I have to be more set up and really pay attention. But, I care a lot about it and still keep my best example on the welding bench, as I try to surpass it with a new best. Only I would know the difference, though. I've always done that. As with everything I do, it has to be the best I've got.
If you need a set of RedLine Deep V bars for your build or just to have. I think you'll be happy with the ones I make. Not cheap, but great pedigree and low quantity.
Frequently asked questions
What is the width of these bars?
They're 26' at the widest point, just like the originals.
Why is there no knurling?
Although knurling was done on all subsequent V-Bar designs, it was not originally done on this model. I never make a change to a re-creation unless it will make an improvement that will NEVER be noticed, so that's not too often. These are nostalgia pieces. I make them like they were. As I say a lot, the only difference is half a century. And, I mean it!
Are they chrome or nickel plated?
They're high polished and nickel plated, just like the originals.
Where are your products manufactured?
"Custom Shop" pieces like these are made by me in my East Texas shop. Others are made by skilled craftsmen who have worked with my dad for decades. I will always specify.
When will it ship, what does shipping cost and do you ship internationally?
If it's offered, it will ship within a couple of days. No pre-sales. Shipping is free to the USA. As of now, I am not shipping internationally. That may change.
"Bottom line, these Custom Shop Deep V-Bars are the most authentic BMX re-creations out there. There's RedLine DNA all over them."