Bending aluminum question

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Hello,Haven't been on in a while, but have a question related to bending aluminum.  I recently bought my wife a Honda Rebel motorcycle.  Everything fits her except the brake lever which she can't really reach (very small hands).  The only suggestion I can find for fixing the problem is bending the brake lever.  The local shop told me to heat it and bend it.  My main concern is it breaking off during use after bending it.I guess my main question is what would be the best way to do this?  I have a plumber's torch, vise, etc.  Thanks!
Reply:If the bike has a hydraulic front disk, you might be better off filing the pad that contacts the piston in order to the bring the lever closer to the bar.  I would also make sure that the front brake isn't at all spongy, or the reduced travel may well make the brake completely ineffective.  It is possible to bend an aluminum lever with a some heat applied with a propane torch, which I have done a couple of times to return a bent lever to it's original shape, but I have broken the lever as often as not.
Reply:If the lever is cast aluminum, heating and bending will crack it.Blackbird
Reply:Originally Posted by dave powelsonIf the lever is cast aluminum, heating and bending will crack it.
Reply:Its cast,welded several. Notch, bend, weld or cut apart and weld. Most have a clear coating- grind it around joint for better weld. 4043 filler.PeterEquipment:2  old paws2  eyes (that don't look so good)1  bad back
Reply:The ductility of most aluminum alloys . . . wrought or cast . . . increases significantly when heated to 350-400°F.  That's also below the temperature for annealing, and a short exposure will have only a small affect on its strength after cooling.  I'd try bending it with some heat . . . check for cracks , , , notch and weld only if it breaks.  jim
Reply:Thanks for the input guys.I guess I am going to try heating and bending slightly.  Even with a 1/2" bend there will still be plenty of travel left.  This thing sticks out a good 3" or more from the hand grip.I read on a Rebel forum that you could put soapy water on the lever and heat until the soap turns black and then bend.  They claimed that would give you a good indication of the temperature and to ensure you don't turn the lever into a molten pool.  Does that make sense?  Any tips from you guys before I give it a try?Thanks!
Reply:Originally Posted by wicrulesThanks for the input guys.I read on a Rebel forum that you could put soapy water on the lever and heat until the soap turns black and then bend.  They claimed that would give you a good indication of the temperature and to ensure you don't turn the lever into a molten pool.  Does that make sense?  Any tips from you guys before I give it a try?Thanks!
Reply:Check out  located in Minnesota. They have adjustable clutch & brake levers listed in their metric bike catalog.
Reply:Tempilsik, or a non contact thermometer
Reply:Hydraulic brake calipers are self-adjusting. "sanding down" the brake pads will not move the lever closer . It will only result in reducing the life of the pads.
Reply:Originally Posted by skelchneHydraulic brake calipers are self-adjusting. "sanding down" the brake pads will not move the lever closer . It will only result in reducing the life of the pads.
Reply:Originally Posted by welds4d . . . or a non contact thermometer
Reply:Do a search on Cycle world magazine, Cycle, Motorcyclist mag. websites. Search brake levers, and you will get some better results for your situation. If that lever snaps while she's in the middle of braking.....she will find herself in the middle of PANIC braking!And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Originally Posted by ironmangqHe is talking about the small nub on the lever that presses the piston into the master cylinder. making it shorter will move the lever closer to the bar. I agree if it doesnt work you can order an adjustable one, Denniskirk is a great company, I order from them often enough and they almost always get it shipped the same day and you get it within a day or two.
Reply:Originally Posted by Old SkoolCheck out  located in Minnesota. They have adjustable clutch & brake levers listed in their metric bike catalog.