How To Make A Bar-End Tubeless Tyre Repair Plug

How to make a tubeless tyre repair plug
If you've read my post 'Top Tips for Tubeless Tyres', you'll know that a tubeless 'plug' is a really useful device, for plugging larger holes in a tubeless tyre that your sealant is struggling to fill.

The idea of a tubeless plug is pretty simple. It is a needle with a strip of rubber threaded through it; to plug the hole, you push the rubber strip into the hole, then pull it back through just enough to leave the rubber strip wedged in the hole. You then cut off the loose ends with some scissors or a knife.

Tubeless plugs, or bungs (as they are also known) are great at filling in flint cuts and other puncture repairs that your tubeless sealant is struggling to solidify in.

The only trouble with them, is that the sharp needle isn't the ideal thing to house in your saddlebag, next to your inner tubes (for obvious reasons). More pressing though, is that in order for a tubeless plug to work, you to get it into the hole pretty quickly; so having it accessible is crucial.

For both of the above reasons, I've found storing your tubeless plug in one of your bar-end plugs, is ideal. Here's how to make one...


Kit required

  • Spare old inner tube
  • Small scissors
  • Large sewing needle
  • Rubber bolt cover
  • Presta valve cap
  • Bar-end plug


Step 1 - Push the valve cap into the rubber bolt cover, then push the sharp end of the needle through the two - effectively hiding the sharp end of the needle

How to make a tubeless tyre repair plug to house in your bar end


Step 2 - Place the bolt cover inside your bar-end plug, then pack Sugru into the cavities: creating a cone around the needle to add extra strength. Leave for 24 hours to set.



Step 3 - Cut a thin strip of inner tube with your scissors. Thread it through the eye of the needle.

How to make a tubeless tyre repair plug to house in your bar end


An even simpler option is to tape a needle from a tubeless repair kit, inside a bar-end plug.

How to make a tubeless tyre repair plug to house in your bar end


Step 4 - Now you can safely house the plug inside your handlebars. Ready for action.

How to make a tubeless tyre repair plug to house in your bar end


A homemade tubeless tyre plug, easy to grab when your sealant is struggling...

How to make a tubeless tyre repair plug to house in your bar end


Note: keep the scissors and spare piece of inner tube in your saddlebag, so that you can chop off the end of the plug when you've used it, and make a new strip.



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