6.38 kg full suspension 10Spd . My final build .

Discuss light weight issues concerning mountain bikes & parts.

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SK5
Posts: 76
Joined: Fri Jun 23, 2017 4:03 am

by SK5

Ok so this frame has been doing the rounds on my last few projects . It went from an all mountain style mtb to 10spd standard mtb to single speed mtb . Well this is the final version . 10 spd front and rear adjustable suspension, large frame and front and rear discs .

Now I just want to say that this setup is how I like it and is the fastest setup for me . If it were a 29er I have done some calculations -

there is a 40 grams difference in rim weight between 26 and 29 . Spoke is about 0.8 grams so in total that is 108.8 grams . Adding another 2 bigger sprockets to make 12spd (aluminium) would be around 60 grams . It's already a large frame and can take 29 wheels and the fork can take 29 wheels too . Tubes are the lightest you can get (38 grams) and the weight difference is about 6 grams each so 12 grams . Tyres are maxxis 285 tyres and the 29 version is 345 grams so difference is 60 grams so total 120 grams . So in total for a 12spd 29er you are looking at 6.620.8 grams . Still nothing lighter that exists .

Here is a description of the work done :


Frame: Scott Spark LTD Edtion carbon 2010

All paint and clear coat removed and sanded to 2000 grit and carbon polished
Shock pivot axles hollowed out further and deburred
Swingarm and linkage mount bolts replaced with anodised blue torx titanium bolts fully hollowed
Gear hanger replaced with custom 7075 T6 hanger finished with custom titanium torx bolts (heads machined down and stem machined in the latheand bolts hollowed in the drill press )
Base and top of headtube machined by 1mm to take new headset bottom and top cup
Bottle bosses machined down and excess bosses on the down tube and bb shell sealed with Schmolke carbon bolts epoxied in place
Shock links anodising removed using router and machined down in areas to save weight
Shock mounting bolts replaced with custom blue titanium bolts fully hollowed in drill press
Anodising removed in areas of the frame just for looks

Rear shock: custom carbon DT Swiss

With lever removed and shaft stamped for hexagonal shape (for Allen key) to save weight
Finished with custom black reducers
Valve cap replaced with forged carbon (Hopp carbon cap machined down in the lathe to make small cap then edges deburred)

Fork: RockShox WC carbon fork

Rebound damper replaced with NDTuned custom air damper
NDTuned cap, bolt and rebound knob replaced with forged carbon parts (by Hopp carbon) and Schmolke bolt (machined down in the lathe to fit the cap)
Hopp carbon air cap machined down in lathe to make smaller and ligher
Air compression and rebound rods replaced with ND Tuned custom black rod
Fixing bolts replaced wth ND Tuned gold torx bolts
Fork brace machined out using the router and then metal polished
Steerer cut to length
1184grams
Custom Schmolke fork plug – slightly tight so machined down in the lathe and reinforced with more epoxy resin
Fork axle – Custom carbon and aluminium axle by Shift UP with head machined in the lathe to save weight and all anodising removed - 21 grams
Custom fork leg graphics in copper and gold metallic and matt mix - 2 grams

Rear skewer

Custom made using aerospace grade m5 hollow rod measured and cut then threads made at both ends using 0.5 pitch (instead of standard 0.8)
One end threads 0.6mm in length to accomodate the secure nut and other end 12mm in length for adjusting nut
Nuts made by Tune machined in the lathe to reduce diameter, all anodising removed and splines machined further using router
First of its kind fully hollowed skewer at 11 grams

Custom Extralite headset

Custom Darimo bar and stem combo

Bar slightly shortened and carbon polished
Bolt holes slightly recessed using sanding square edged drum
Bolt replaced sith custom blue torx titanium bolts fully hollowed

Custom Extralite grips (4 grams for pair)

Shortened and tapered in the lathe

Custom Extralite bar plugs (Less than a gram for the pair)

3D printed and slightly sanded to aid grip

Silicon bottle boss plugs in red by Silicon Tidds

Custom saddle by Gelu (56 grams)

Custom graphics sent to the company to be put on the saddle and then clear coated

Saddle fixings

Custom carbon yoke clamps one made by Darimo (top section narrowed in the center and arms narrowed to save weight)
Custom alumnium nut for yoke clamp made using 7075T6 billet, shaped, drilled and 5mm threads tapped
Second Yoke clamp custom made using T800 carbon rod and carefully machined to shape
Custom nut made from 7075T6 billet and shaped to lock into yoke clamp
Titanium m5 bolt heads machined down in the lathe and stems narrowed then completely hollowed in the drill press

Extralite bb cups

THM carbon cranks

Axle splines drilled 20mm deep to save weight
Crank pinch bolt completely hollowed in drill press
Barrel nut compeltely hollowed
Custom carbon axle spacer by New Ultimate (shortened and inner diameter increased to fit)

Rare custom pedals by Aerolite (46 grams for the pair)

Axles custom reinforced coated aluminium (said to be nearly as strong as titanium) completely hollowed
Pedal bodies made from carbon fiber with Zytel Nylon inserts (new version for 2024)
Aluminum end caps replaced with custom carbon caps made from 6k thick sheet carbon fiber T800
Original fixing bolts machined down in lathe and shortend and tapered with all anodising removed

Custom carbon fiber chainring

Made from thick sheet of T800 6k carbon fiber carefully cut and fully tested - only one of its kind for this crank

YBN 11spd silver and gold ti nitride coated titanium chain (all rollers are titanium and less than 200 grams)

Custom 10spd gold mono block cassette

10th sprocket made from aerospace grade titanium billet and fully tested
Finished with gold Extralite lockring

Custom XTR derailleur

XTR logo removed
Body heavily machined in areas to save weight using router
Carbon back plate arm by Hopp carbon
Custom Eztralite jockey wheels
Custom gold jockey wheel bolts fully hollowed in the drill press
All limit screws and tension screws are torx titanium anodised blue fully hollowed

Custom gold coated titanium gear cable by KCNC

Shortened and finished with custom gold screw on crimp

Custom Nokon carbon outer cable housing with Powercrdz lining cut to length

Shimano XTR shifter

Lever drilled and oval shape created using the router then tapered
Mounting bolt is dlc coated black titanium torx cut to length and tapered in lathe and fully hollowed

Custom carbon composite shifter/brake clamp by Tune

Base of clamp carefully machined and reshaped to match top of shifter so they mate properly
Bolt holes slightly recessed using square edged grinding drum


Custom brakes by BrakeForceOne (updated magnetic version)

Caliper bore caps replaced with custom blue and red versions
Lever body reshaped in areas to save weight and some anodising removed
Lever body all anodising carefully removed
Lever bolts replaced with custom blue version completely hollowed
Pad pins replaced with custom titanium
Pads replaced with custom aluminium backed pads to save weight
Hoses replaced with custom glow in dark hoses and custom aluminium barbed inserts
Removed left lever body and replaced with custom hose splitter made from 7075 T6 alumium anodised
Barbed insert to brake lever body replaced with custom gold titanium version to cope with increased pressure
Lever body clamp bolts replaced with custom black titanium torx bolts completely hollowed
Lever body to shifter bolt replaced with custom black titanium torx bolts completely hollowed
Caliper bolts replaced with custom dlc coated black titanium torx bolts fully hollowed

Rear brake caliper adpator by BrakeForceOne

Finished with custom dlc coated black titanium torx bolts fully hollowed

Scrub disc rotors (discontinued)

Rear disc carrier machined away to a three spider (instead of 6 and fully tested) and fully tapered
Finished with Extralite titanium rotor bolts all hollowed in drill press

Wheelset

Custom Tune Prince and Princess hubs with carbon and aluminium flanges
Rear hub disc tabs cut off (three)
Custom white CX Ray spokes custom laced with blue and gold Sapim nipples (alternating)
Custom Prototype Carbon rims (less than 300 grams each and from Portugal)
Excess spoke holes reinforced with additional carbon and bolt holes reinforced with carbon and carbon kevlar cured in bag

Custom RideNow TPU tubes (36 grams each)

Maxxis 285 tyres

Tune
Gelu carbon creation
Scott Racing Team
DT Swiss
THMbike
RockShox
ND Tuned
HOPP carbon parts
Sapim Spokes Philippines
Darimo Carbon Fiber
@scrubrotors
BrakeForceOne
Extralite Racing Products
Schmolke carbon & AX-lightness Taiwan distribution 台灣代理
@nokoncables
Aerolite Pedals
Shimano-MTB
Trialtech Components
KCNC
Easy Composites Ltd
Agogo Bike
Cycle Taiwan
Yaban Chain
TitaniumPlanet TP
Shift Up
RideNow Store
Maxxis Tires
r2bike
BIKE24
Bikeonline.it
DuLight

#thelightest
#carbonnutcase
#worldrecord
#fullsuspension
#bike
#makeityourself

My website:

sebklightbike.godaddysites.com

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Here some more pics of parts both bought and made :

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Changed the chainring size .

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Hollowing these splines was not easy and delicate work .

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Last edited by SK5 on Sat Mar 30, 2024 5:13 pm, edited 3 times in total.

by Weenie


Visit starbike.com Online Retailer for HighEnd cycling components
Great Prices ✓    Broad Selection ✓    Worldwide Delivery ✓

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bikewithnoname
Posts: 1737
Joined: Tue Sep 22, 2009 1:29 pm
Location: Paris

by bikewithnoname

Nice work! I'd pump up your tyres before hitting the trails though😆
"We live in an age when unnecessary things are our only necessities." Oscar Wilde

rhender
Posts: 74
Joined: Fri Nov 05, 2021 4:49 pm

by rhender

This bike is the reason I use this forum

User avatar
SK5
Posts: 76
Joined: Fri Jun 23, 2017 4:03 am

by SK5

bikewithnoname wrote:
Fri Mar 29, 2024 8:34 pm
Nice work! I'd pump up your tyres before hitting the trails though😆
Definitely :) :) !!!

User avatar
SK5
Posts: 76
Joined: Fri Jun 23, 2017 4:03 am

by SK5

rhender wrote:
Fri Mar 29, 2024 9:06 pm
This bike is the reason I use this forum
Me too :) :) !!!

User avatar
LeDuke
Posts: 2052
Joined: Sun Oct 07, 2012 2:39 am
Location: Front Range, CO

by LeDuke

No tension in the spokes, eh?

Let's see how that works out.

User avatar
SK5
Posts: 76
Joined: Fri Jun 23, 2017 4:03 am

by SK5

LeDuke wrote:
Sun Mar 31, 2024 4:46 am
No tension in the spokes, eh?

Let's see how that works out.
Spokes are fine .

by Weenie


Visit starbike.com Online Retailer for HighEnd cycling components
Great Prices ✓    Broad Selection ✓    Worldwide Delivery ✓

www.starbike.com



EtoDemerzel
Posts: 339
Joined: Sun Dec 17, 2023 4:13 pm

by EtoDemerzel

Fantastic build
spank bank ww hall of fame

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