Handlebar Gear Support?

[Littlewheels]

Hi,
I am in search of a series 3 handlebar gear support, the type that fit the thinner levers and has the raised part around where the pivot pin sits.

Mine is beyond repair (I think?) as it has been drilled out to 10mm

Thanks

[Warkton Tornado No.1]

Can't you get it bushed to reduce the hole to the correct size?

If you don't have the confidence or equipment to do so yourself, you may know an engineer that will fix it for you.

I wouldn't suggest the bush be aluminium alloy. An Oilite bush or stainless steel would be good. For instance, Oilites are available @ 6 mm bore x 12 mm OD that is a bigger 'envelope' than you need for less than a quid, so there will be something even better you can use or modify to fit well.

Once fitted, the lever pivot head & nut/washer will hide any evidence.

[Littlewheels]

I have measured the hole and it is 9.5mm. The diameter of the pivot pin head is 10mm so not much room left. Also the hole is out of shape so by the time you machine it round it will be more like 12mm!
Going to get it welded then drilled and reamed the correct size.
Will post pics of before and after if it's successful but thanks for trying to help.

[Warkton Tornado No.1]

The hardest part will be getting a good weld that matches the colour with no porosity, but Good Luck!

TBH I hadn't realised the head of the pivot pins were so small!

I like to try & keep everything that I do 'in house' & only have oxy-acetylene so I tend to think of options that I could carry out myself. I've not had a great deal of success when farming out alloy welding, even with coded welders.

So I guess in your circumstances I would have to fit a top hat bush from inside the lever (narrow enough to slide into the slot prior to being pressed home) with probably a bigger bush (to match the top hat bush 'brim' diameter) @ the bottom of the lever where the special wavy washer should conceal the fix. Fortunately II have a small lathe & pillar drill. The lathe takes cylinder heads on a fixture I made but I struggle with spigotting cylinders when I have to spigot the top..