How To Cut A BMX (Or MTB) Handlebar

Cutting bike handlebars can seem tricky at first, but it doesn’t have to be.

In fact, it’s WAY easier than you think.

Whether you ride BMX or MTB, getting the right handlebar length/width will make your ride more comfortable and boost your control.

I ride my bar at around 28″, which is perfect for pretty much everything – and the barspins spin fast, too.

In this guide, I’ll share with you three simple ways to trim your bar just right.

Quick Overview Of The Bar Cutting Methods

• Pipe cutter (my top pick)
• Hacksaw
• Angle grinder

Why Choose A Pipe Cutter?

Among the three, a pipe cutter stands out as the easiest, safest, and fastest method.

No sparks, no messy edges, and way less chance of damaging your bar.

I highly recommend the Knipex TubiX Pipe Cutter for its rugged build and precise cuts.

I’ve used it countless times on my and my friends’ bikes, and it never disappoints.

You can get yours HERE.

How To Cut Your Bike Handlebars

Method 1: Pipe Cutter (Fast & Clean Cuts)

Tools You’ll Need:

• Knipex TubiX Pipe Cutter
• Marker
• Tape measure

Steps:

1. Measure twice, mark once: Use your tape measure and mark the handlebar where you want to cut. A quick tip: wrap a bit of masking tape around the bar to protect the finish and give a clear cutting guide.
2. Adjust & lock: Open the Knipex TubiX, position it on the mark, and quick-lock it. The one-handed QuickLock system makes this insanely simple.
3. Rotate & tighten: Turn the cutter around the bar, gently tightening after each full rotation. The hardened steel cutting wheel and four guide rollers will slice through metal with minimal friction.
4. Deburr edge: Flip the cutter to use the built-in deburring tool in the handle. A quick pass removes sharp bits.

Pros:

• Smooth edges every time
• No sparks or heat
• Minimal effort

Method 2: Hacksaw (Budget-Friendly)

Tools You’ll Need:

• Fine-tooth hacksaw
• Vice or clamp
• File or deburring tool

Steps:

1. Secure your bar: Clamp the handlebar in a vice or to a sturdy workbench.
2. Mark & saw: Draw your cutting line and saw slowly along it, keeping the blade straight.
3. File down edges: Use a fine file or a deburring tool to smooth the cut. Be patient – rushing leads to jagged edges. File down both the outside and the inside of the tube. If you don’t do the inside, you’ll have trouble inserting bar ends.

Pros & Cons:

• Inexpensive and easy to find
• Takes more time and effort
• Edges can be rough without proper filing

Method 3: Angle Grinder (Quick Cuts With Safety Precautions)

Tools You’ll Need:

• Angle grinder with a metal-cutting disc
• Clamps
• Protective gear: gloves, goggles, ear protection

Steps:

1. Prep & protect: Clamp your bar. Wear full safety gear. Sparks will fly!
2. Line up the disc: Position the grinder at your mark.
3. Make the cut: Sweep the grinder gently through the bar. Don’t force it; let the disc do the work.
4. Smooth the edge: Finish with a metal file or sandpaper. (Again, smoothen the outside and the inside edge.)

Pros & Cons:

• Fast for thick tubes
• Danger of sparks and heat damage
• Requires more cleanup

Comparing The Methods

Why The Knipex TubiX Is A Game Changer

Made in Germany, the Knipex TubiX features a coated magnesium frame that’s rugged yet lightweight.

Four guide rollers and a hardened steel cutting wheel roll on needle bearings, so every cut is smooth.

The QuickLock system lets you adjust on the fly, and the built-in deburring tool cleans up your work in seconds.

It handles pipe diameters from 6mm to 35mm and wall thickness up to 2mm – perfect for handlebars, steerer tubes, and seatposts.

Yes, you can even cut the S&M Hoder bar!

Maintenance Tips

• Keep the cutting wheel clean and replace it when dull (spare in the handle).
• Lubricate the adjustment screw for smooth QuickLock action.
• Store in a dry place to prevent corrosion.

Conclusion: Cutting Down Bike Handlebars Is EASY!

Cutting your own handlebar is a satisfying, cost-saving DIY.

Yes, with the right tool, you can do it all by yourself – no need to pay someone to do it for you.

For every rider – BMX or MTB – the pipe cutter is the go-to tool.

It’s fast, precise, and safe.

I’ve been there – fumbling with a hacksaw, filing edges for what feels like forever, and still ending up with jagged bits that catch my gloves.

Not to mention, my cuts were never straight!

Switching to the Knipex TubiX Pipe Cutter was a total game changer.

Suddenly, trimming steerer tubes and handlebars became a one-handed, five-minute job.

No sparks, no noise, no sweat – just smooth, perfect cuts every time.

I. Love. It.

You just got your new 30″ wide bars and you’ll like to go have a session ASAP.

Luckily, the freedom of a solid pipe cutter make it happen for you.

It’s lightweight, built tough, and even packs its own deburring bit.

Every rotation glides, thanks to four guide rollers on needle bearings.

That means less effort for you – so you can have a session with fresh not tired arms.

If you want the easiest, safest, and fastest way to cut your bars (and pipes around the house), the Knipex TubiX Pipe Cutter is the one to get.

Trust me, your hands – and your bike – will thank you.

Grab yours today and see how simple handlebar trimming can really be.