Here's a small collection of tips and tricks I use in the shop, and one I use while out riding. If you have more, put them in the comments!
Penny + Quill Stem
We've all been there. Unwrap your new drop handlebar and immediately scratch the bend trying to get it through the quill stem's clamp. Then you sigh and say to yourself, 'it's okay, tape will cover it up'. If your stem clamp has a threaded portion, put the bolt through the backside and tighten a penny. It will keep the clamp expanded and you'll be able to open it up a bit to more easily slide the bar's curves through the clamp without damage. If you have a threadless design like a Nitto, find a thin nut to place in the clamp for the screw to thread through.
If you're cutting a bolt for a better fit, thread a nut further down than the cut. When you unthread the nut, the threads are automatically cleaned up!
The clamp and body of non-aero brake levers are much smaller than their aero counterparts. Being able to see the clamp through your new bar tape is unsightly and detracts from the appearance. When you've set up the position of the levers, put some scotch tape on the clamp to hold it in place. Unscrew the body from the clamp. The clamp should stay in place by the tape. Wrap around the clamp and screw the body back on. Voila! No embarrassing clamp is visible through your wrap.
This one I picked up from Mark. Our fender eyelet bolts are absolutely perfect for guiding dynamo wires. Zipties should be kept to an absolute minimum on a bike. Yes, I did use a few zipties. I am ashamed. The back is in need of severe de-ziptieing. De-ziptying? De-zipting? Anyway, use a couple washers to achieve optimal guiding of wires.
|P-Clamps are acceptable|