DIY: Converting Ergopower to Super Dummy LeverComments
by Mark V on Jan 31, 2012 at 8:02 AM
When it comes to the ergonomics of dropbar levers, Campagnolo absolutely nailed it with their third generation Ergopower. I want these for my fixed-gear handlebar, but unfortunately the levers have that annoying and useless shifter mechanism. So in order to convert a new set of Ergopower levers into something really useful, namely the most comfortable brake levers ever, here’s what you do.
1 Gut the shifters.
2 Cut the cross section of the shifter cavity into thin cardboard
3 Trace cross section onto 2x4”
4 Start carving
5 Keep carving. The righthand unit is purely a dummy lever, so the goal is to completely fair in the gap underneath the body and replace the brake blade, since without the shift mechanism there is no return spring to keep the blade from rattling without a brake connected. With lefthand unit, you’re trying to fair in the underneath and as close to the blade as possible while still allowing the blade to complete its travel all the way to the handlebar.
6 Now that the carving and sanding is done, ideally I’ll get these painted to protect the wood and to improve aesthetics. I’m still considering options for that.
After the jump, see photos of intermediate stages.