OK, one more post. :-)  Here's how I made the expander...

http://twowheels.us/bicycles/vrex_headlight.html

On Thu, Dec 29, 2011 at 10:35 AM, Rex Kerr <rexk...@gmail.com> wrote:

> Actually, I take that back... my expander was a bit different than that...
> I remember now that I used some of those threaded table leg inserts for
> allowing you to put adjustable feet on the bottom of table legs.  They have
> sharp spikes that poked into the rubber plug to keep them from rotating
> while I was tightening or loosening.  I'm looking for pictures, but they're
> in a deep dusty corner of my website from years ago...
>
>
> On Thu, Dec 29, 2011 at 10:33 AM, Rex Kerr <rexk...@gmail.com> wrote:
>
>> Are they merely friction fit?  I don't see any expander mechanism.
>>
>> In the past I've created expanders by using a rubber plug with a hole
>> through the center and a large washer on the other side.
>>
>>  On Sat, Dec 24, 2011 at 3:52 PM, Andrew <ashtab...@gmail.com> wrote:
>>
>>> I miss the bar-ends on my Quickbeam, where I'm used to gripping and
>>> resting my hands on the other bikes. So I made some plugs out of aluminum,
>>> to give back the extra length that you get with bar-end shifters. They
>>> match the external diameter of the bars (24.0) and have a very snug hand
>>> fit inside. These aren't done - I need to hollow them out, and I haven't
>>> decided whether just to use strong Loctite, or to rig a screw & cone
>>> internal stopper.
>>>
>>> I figured out flikker:
>>> http://www.flickr.com/photos/71141757@N02/6566387189/in/photostream
>>>
>>> But still prefer SmugMug: diesel.smugmug.com/Bici/M-Bar-plugs/
>>>
>>> Once I get them attached, I'll finish up the rest of the cockpit (stem,
>>> tape, brake cable routing, VO bell mount). But for now, they stay in, and
>>> they ride great!
>>>
>>> - Andrew, Berkeley
>>>
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>>
>>
>

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