Bicycle tool that nobody knows and what you can do with it - fork cutting guide

UPDATE: In an initial version of the article, we did not clamp the fork cutting guide in the vice for clarification purposes. To avoid confusion during use, the images have been replaced and the correct version is shown.

When you get a new suspension fork for your beloved bike, the steerer tube has a maximum length to accommodate all steering heads and spacer bars. However, in order to cut the steerer tube to the right length for your own MTB, you need to use a rough tool: a saw. Incidentally, this applies to both carbon and aluminium steerer tubes. The only difference here is the saw blades - more on that in a moment.

In order to achieve a surgically clean and, above all, straight cut, i.e. exactly at right angles to the shaft, we have developed our...

Bicycle tools that nobody knows - Part 1

One of the bike tools that nobody knows is the Fork cutting or saw guide. It is inconspicuous, tends to hide in the lower part of the toolbox and can really only do one task properly. But it does so with the necessary accuracy and endurance.

Unlike the name - FORK cutting guide - suggests that it can be used to cut all kinds of tubes and, of course, handlebars. On our model of the Birzman saw guide, the opening holds a maximum of 34 mm thick tubes, which should even fit the ends of a 35 mm DH handlebar - only the thick 34.9 mm seatposts won't fit. Thanks to the oval opening of the guide and a corresponding toggle, it can also be used to cut aerodynamic tubes. All you need is a saw!

In our case, the saw guide is designed for a narrow metal saw for aluminium components. If you want to do everything right, you need a special carbon saw for carbon tubes, which has a slightly wider saw blade. Instead of the familiar saw teeth, this has a grit - similar to a nail file - so that the carbon fibres do not fray during sawing. There is a special saw guide with a wider guide for their use. Attention: Note at this point - always wear suitable respiratory protection when sawing or sanding carbon material!

How-to: How do I use the fork cutting guide?

First mark the planned cut on the steerer tube - preferably clearly visible, as the tube will then be slightly covered by the saw guide. Clamp the saw guide firmly in a vice. Then insert the steerer tube into the guide and position the marking where the slot between the screwed-on plate and the main part of the guide is and lock it in place.

The hacksaw can now be lowered into the guide and sawn to your heart's content without jamming. Incidentally, it is advisable not to move the saw blade back and forth too hectically or quickly, otherwise it will get hot, your arm will get tired and the cut will still be unclean. It is better to move calmly and with courage. At the end, the edge should be deburred on the inside and outside with a metal file - this way the stem claw goes into the steerer tube more cleanly and you avoid nasty aluminium splinters in your fingers.

For just under 20 to 80 euros - our Birzman saw guide currently costs around 22 euros (e.g. available here) - you have a very practical, long-lasting bike tool that makes short but very effective work easier.

In the next instalment, we will once again be presenting a bike tool that nobody knows about. How about a brake pad spreader, a chainring bolt spanner or a dummy fork?