Here in my country is kind of difficult to get certain types of handlebars, but it is easy to get flat and riser mountain type handlebars and standard types of road drop bars.
So I'm investigating whether it is possible to purposefully bend a straight handlebar to have it in another shape.
Can it be done with common store-bought tools? If not, I can take it to a metal working shop and get it bent there? Will it be safe?
In particular, I'd like to turn straight handlebar into a bullhorn shaped one.
I'd like to have this done on aluminum but i'm not sure whether a finished handlebar can be bent.
A second option is to make the handlebar out of steel pipe that is easily bought locally. However to install it on a bike shims will be needed to make up for the "bulge" that handlebars have in the clamp area.
I have currently configured my bike with a short straight handlebar fit with bar ends and it works pretty well for my purposes, but I'd like to have a rounded curve instead of the sharp angle that the bar and bar ends have.
I currently do not have the means to buy a ready-made bullhorn via internet by myself, but if I had, the hassle of shipping, customs taxes and other annoyances made me wonder if making my own is feasible.
I have desisted from the bend-to-customize route. My riding circumstances have changed so I no longer "need" this setup, In fact, I reverted that bike to regular MTB handlebar and tires.
I plan to convert another hybrid sometime in the future, but no time goals set. I will do it with a commercially available handlebar, just need a more elegant solution for cable routing.
The next picture was taken just prior to disassembly to return the bike to MTB form. This setup worked pretty well both for commuting and road riding. It offered two solid and comfortable hand positions. The only dislike I had, was the bulge that the bar ends clamp caused in the corner, and I was looking for a way to have a curve of uniform diameter instead.