Flatbar trimming
 

Any downside to shortening an aluminum bar with a hacksaw?I’ve got a short wingspan and the 640mm is just too wide.

As long as you keep it straight it'll be fine. I use a pipe cutter. As always, measure twice, cut once.

No issues, but unless you have a guide for the saw it‘s hard to cut it straight. I use a rotary pipe cutter.

And you might be surprised at how easy it is to take off too much. Start with a smaller reduction than you think you need.

Excellent tip about the pipecutter. I even have one,thanks guys.

Make sure you move the brake shift levers to the new position before marking/cutting. You don't want to find out you cut a bit too much.

You'll need a file or emery cloth to remove the burr. My tubing cutter leaves a knife sharp one. Not large, but VERY sharp.

/ yea \
Loosely mount grip, levers & bar end before you cut. Be sure it all mounts just outside the bend radius.

640 is too wide? These days those are handcuff handlebars.

No matter whether yo use a hacksaw or pipe cutter, use a reamer or deburring tool on the cuts. I usually prefer the reamer. It’s faster than using a file.

Not to judge, but no idea about what sort of bike the Op is asking about

It’s the Windsor Tourist I bought for mostly pavement fitness riding and some bikepacking with gravel.I’m a short old guy(5’4)and they use the same bar length for all their bike sizes plus I mistakenly bought a size larger than I should have. I took 1” off each end giving me 23”(585mm).

^^^This.^^^

As the joke goes, if you cut off too much, just cut off a little more.

“I cut my handlebar three times and it’s still too short!”