Friction fit, with permanent loc-tite, was my first thought. That lets me
hollow them out all the way through. Your suggestion of an expander
butt-plug is good, and I have been tinkering with that, too. Would probably
run a rubber donut against the end, with a washer and captive nut on the
far side, and then bore out most of the extender, but leave a face inside
that a small bolt could face against, to tighten the washer - and bulge the
rubber donut. We'll see.

- Andrew, Berkeley

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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