this might help.................July 6 2012 at 7:17 PM
SgtVimes (Login SgtVimes)
Response to yes
Bending it any amount when too cold creates minute internal fractures which mean it will snap, either immediately or during use. But this numptyness doesn't mean the answer is never.
An old trick is to put soap or fairly liquid on it, then heat until the soap just starts to go brown, then bend it back into shape.
Is the right answer. Done it to the same lever 5 times on a dirt bike, and it would have been 6 but it bent double on the 6th time. I've also used it to bring levers closer to the bars for GF's bike (fuck the kittens, I'm an engineer).
Soap browns at 450 Deg C. Alu melts at 650. TBH I don't bother with the soap, I go by feel.
Hold the lever in a vice and have a length of pipe ready that will fit over the end. Also have a cardboard box. Put pressure as if to bend (but don;t) to get a "feel" for the amount the lever flexes. Heat the lever uniformly by playing the flame over the bend and about 1" either side. Give it at least a minute. Try the "feel" again. When it's hot enough, the lever will resist about 1/4 amount to your testing. Then it is ready, it will bend very easily without damage. Soap can help, but some modern soaps go brown at much less than 450DegC. If it's very bent, don;t do it all in one hit. Heat + bend, heat a bit more + bend, etc.
Cool it slowly. Do NOT dunk it in water, you will make it brittle. Put it on a non-combustible surface (preferably not anything like steel which will suck the heat out of it) and up-end the cardboard box over it to restrict air-flow. Leave it until cool.