Sewing - Bike Handlebar Bag

handlebar bag, top view

handlebar bag, rear view

Carries neckpurse and its contents. No closure needed, since friction sufficient to keep neckpurse from bouncing out. Lack of closure makes it easy to retrieve neckpurse, and thus maps, guidebooks, smartphone and other items carried inside neckpurse. Weighs 235 grams.

Hangs from handlebars, supported by dual Thorn 105mm x 0° accessory bars (110g each, ordered from SJSCycles) to keep away from brake levers and cables. Total weight of both accessory bars plus handlebar bag is thus 2 x 110g + 235g = 455g. Compare with Ortlieb handlebar bag at 700g for the size large, which is much smaller than my handlebar bag and also less convenient for me. Small size of Ortlieb bag means it does not allow for 12" wide Aloksaks or maps folded to about 10"x10", such as my Lassen map. Only advantage of Ortlieb bag is waterproofness. I seldom bicycle in the rain, but when I do, waterproof stuff sacks and 12"x12" aloksaks (both carried inside my neckpurse) work fine to protect electronics and paper items from moisture.

Use 80/12 universal needle and all polyester thread.
Cut two pieces 17.5" wide x 15" high of 1000d cordura. Double-stitch bottom and sides with 3/8" seams, zigzag seam allowances. 1/4" hems at top of bag.
Cut two pieces 16" long of 1.5" wide nylon webbing. Sear ends. Fold and sew webbing to top of bag to form tunnel for aluminum rods. Use bartacks at end of tunnel, since there will be extra stress in this area.
Cut two pieces of cordura, 3" x 8" each, and zigzag edges. Sew two pieces just below tunnel, one on inside and one on outside of bag, and two pieces about 3.25" below the upper pieces. These are reinforcement patches for abrasion against the accessory bars.
Cut four strips of cordura 5" long by 3" wide. 1/2" semi-hems (fold over to make 2 layers thick, rather than folding twice as with true hem) on long sides, to form 4 strips 4" x 2". Cut two 2" squares of hook-and-loop. Stitch hook to coated side of hook straps, loop to uncoated side of loop straps. Attach straps to bag, just below tunnel, about 1.75" between inner edges of straps.
Buy 36" long piece of 6mm (1/4") diameter aluminum rod, which is commonly available at Home Depot and other hardware stores. Cut 2 pieces of 15" and sandpaper ends to make them smooth. Insert one piece in each tunnel. Bend ends using bench vise so that straight section is 12" long.
Fray-check all stitching.