Broken fork control lever clamp

[laura*]

A while back I was doing the final assembly of my new MTB. I was attaching the suspension fork's Remote Control Lever to the handle bars. The RCL is mounted via a little pot metal clamp that goes around the bars. I was tightening the clamp bolt, turning a little itty bitty allen wrench. Suddenly, snick and (from across the room) PING! I hadn't notice before, but the clamp had (had!) a hinge - a hinge which was now broken apart.

I've spent weeks thinking of other ways to mount the RCL. I was considering modifying the clamp assembly from an old shifter or brake lever. However, I held such a clamp up to the bike and it looks really out of place next to all the other new ultra light components. I had originally dismissed the idea of getting an identical replacement clamp. If it broke so easily during assembly, then a quick Oops! on the trail might break the replacement. I'm now thinking of getting an exact replacement for the broken part.

The fork brand is Magura. They're German. Their website has a dealer locator, however it simply returns every bike shop in town that might be able to order from a distributor like QBP. The situation isn't helped by my having bought the fork via mail order. There is other contact information for Magura USA, but it feels like I'll have to shout down a straw.

Any advice? I've been paralyzed with indecision. Meanwhile, the bike sits unused because I don't want to mount the bar ends until I have the RCL clamp sorted out. (Well - the weather hasn't been cooperative enough to even want to take the bike out for a ride.)

[MartianDestiny]

I think my first course of action would be to go to my favorite LBS and see if they could order it, what the time frame was, and what the cost was; then go from there.

A few other thoughts:

1) Is the fork fully functional without the remote? Ie: can you still get to and tweek all the settings? I don't have a remote and don't miss it, my controls, however, are on the top of the fork leg and I can reach down and adjust in any smooth spot or stop for a second. Basically do you really need this part or not? Could you ride the bike without it?

2) If the remote had a hinge, maybe that was so you could open it up and put it on without removing the grips and everything else? If that's the case then I'd put the bike together and ride while making your mind up about the part.

3) Consider lock on grips. Super easy to remove and replace for any kind of adjustment or replacement and have other advantages as well.

[DebW]

Would zip ties do the job?

[Becky]

I think I'd start by calling Magura USA. You never know....it might go really well. I've called other cycling companies with dilemmas, and have been sent free replacement parts.

[SadieKate]

I can't imagine not calling Magura USA first. They also have a forum on their site so you could easily ask others if they have a dealer.

But then, I'd take this opportunity to get rid of the stupid RCL. It just takes up space and weight. I never use the stupid things. I just replaced the fork on my Racer X and the shop accidentally installed the RCL and now the mechanic is pleading with me to try using it more. Why? A good shock and suspension design, and a good pedaling stroke is really the best choice. But just my humble opinion.

[laura*]

But then, I'd take this opportunity to get rid of the stupid RCL.

That requires a replacement DLO cylinder in the fork.

I've never had suspension before and thus don't know how I'll end up using it.

[SadieKate]

Would zip ties do the job?

Probably not. The lever clamps are like brake levers and can rotate easily.

[laura*]

Would zip ties do the job?

No. Unless I was willing to have the RCL just hanging loose.

I have thought of using an automotive hose clamp to "back up" the broken clamp until I get a replacement.

[laura*]

I think my first course of action would be to go to my favorite LBS and see if they could order it

I've lived in my present location for 21 years, there are 11 or so LBS's close enough that I could cycle to them, and yet I don't have a favorite LBS. I've just never had a perfect experience with any of them. It's felt like they are just fronts for the QBP catalog.

One purpose of this thread is to find out just how one gets service parts that are not in the QBP catalog.

Is the fork fully functional without the remote? [...] Basically do you really need this part or not? Could you ride the bike without it?

The bike is rideable, but I can't lock the fork without the RCL hooked up.

If the remote had a hinge, maybe that was so you could open it up and put it on without removing the grips and everything else? If that's the case then I'd put the bike together and ride while making your mind up about the part.

Yup! However, if I were to bodge my own clamp, then there wouldn't be a hinge.

Consider lock on grips. Super easy to remove and replace for any kind of adjustment or replacement and have other advantages as well.

I can't use squirmy pinchy rubber grips. They make my hands fall asleep instantly. Thus I've gotten used to riding with bare metal bars. However, I will be installing old school L-bend bar ends. The ones I've chosen look like they may be tricky to install. Once they are installed, I think they'll need to be left alone. That's why I feel I need to sort out the RCL clamp situation before finishing the build.