How to cut a carbon fiber fork yourself from YouTube’s award-winning guru of bicycle repair. Free Shipping on bike parts, tires, tools, and cycle accessories at Cutting your fork down, threaded or threadless, requires care.


  1. we did many composite builds in the 70's & 80's, Be Careful Carbon Fiber is very tricky at best- the micro shreds cut in process are far worse than fiber glass – Warning * Itching and  other contamination. follow prescribed authorized methods to cut Carbon Fiber * look into experimental aircraft  web sites for more info-  several suppliers  also offer  correct cutting tools…  I will post info  from my archives on this…

  2. the crack is probably from the spreader flang expansion nut  buried in  the tube- do not use this type of expansion nut on carbon fiber , there is a solid plug type nut that allows removal, the spreader nut used in this fork- is a flat plate of metal and will bust out the carbon fiber – manufacturers do not recommend use of these in their products, advise owner  to get the right stuff 

  3. I've used a pipe cutter to trim handlebars and it works great. Cuts perfectly straight and smooth. I'll bet it would work for this too.

  4. FWIW, there are specific hack saw blades for cutting carbon fiber with.  It prevents shredding the carbon and de-laminating it.

  5. ?  No carbon fiber was harmed in the making of this video. And a very good thing that was, judging by rentatrip's cautions. I would feel safer around plutonium.

  6. lighter wheels, lighter handlebar, bb, chainrings, the rest is a waste for commuter bikes, which is all I ride. 🙂
    always wanting to learn how to do things, though.

  7. I trimmed the fork on one of my bikes with an $8 pipe cutting tool from the hardware store.  Probably not durable enough for repeated cutting but it did the job nicely.

  8. Question about the cracked carbon steerer fork – could it be trimmed down and safely used on a smaller frame?  Just curious.

  9. Thanks for the video. I am getting ready to cut a steerer tube on a bike I'm building this morning and couldn't figure out how to get a straight cut. The old stem is accurate and cheap because I have one in the parts box, brilliant. Thanks again.  

  10. You might try a hose clamp as a saw guide. The saw will not cut the stainless steel of the clamp and they are cheaper than the stems.

  11. Nashbar forks. Good company, based in Asia, good build specs, never broke on me. They do have a full carbon for an extra $20. But they're good forks for the price ($110 including shipping) that said, nashbar's warranty is a bit iffy.

  12. That looks like a star-fangled (note not spangled!) nut in that fork. That is a big no-no with carbon steerers and probably why it cracked. Always use an expansion plug with carbon steerers. Star fangled nuts cut into the stearing tube which is fine for aluminum/steel/titanium but compromises carbon.

  13. Nice video. You may also want to checkout the review of diy bike repair on my blog at ericreviews. com/diy-bike-repair-review/ Thanks, Horst.


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