Never throw away bicycle pumps with broken levers! Here is how you can easily repair them!

Few years ago, at the local Bike kitchen, a guy brought 2 bicycle pumps, both with broken levers. No one could fix them, so Filippos took them in his workshop to fix them using his CNC machine. Though this is a superb solution, hardly ever a cyclist has access to a CNC machine. So a year after that incident, I had an idea to repair a broken pump by using a piece of a wooden stick (I always using collect branches from pruning). You can see the article here. Though the pump still works perfectly after the everyday abuse for the last 2 years, the end result looked a bit rough. So, recently on my trip the rock, after an other pump’s lever broke while I was on the mountain, I decided to repeat the hack again, this time by doing a better job. This wooden lever is not going to break and leave you with a flat tire on top of a mountain!

Here is how I did it.

You are going to need: Dremel, small nail, hammer (or any other metal tool you have to hit the nail), a good knife, hacksaw.

1. Find a piece of wooden stick thicker than the base of the plastic lever. Cut it on the appropriate length with your hacksaw.
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2. Using a small nail bang out the metal rod that holds the broken lever in place.

3. Using a good knife, curve out enough material from the stick so it has same the shape with the base of the plastic lever. (pic3)
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4. Using your whittling skills again, make a nice handle out of the other end of the wooden stick. Its pretty easy.

5.Then put it no its place on the pump and test to see if it fits. If it does mark with a pencil where the metal rod will go through.
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6. Use your dremel to open a hole for the metal rod. It should look like the original handle. You can use sandpaper to refine it.
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7. It should look similar to this:
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8. That’s it, test it to see if you have trouble lock/unlock it. You can easily fix problem like this by removing some material. You can see how mine looks!
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