cannondale SuperSix Evo Hi-Mod (5.70 kg)

[HiModular]

Update (18. January 2025)

Weight: 5,70kg including Pedals and Wahoo Mount

Originial Post:
Hey guys - my name is Patrick and I am from Austria / Tyrol.

I take cycling quite serious (here is the strava proof )

strava105.jpg (8.21 KiB) Viewed 1487 times

I am lucky enough to live in the tyrolean mountains and I want to build a pure climbing bike.

I recently bought a cannondale supersix evo himod from 2014.

It has a cracked top tube which I will repair (I have some experience with carbon repairs already).

Then it will get a matt black paint job (2 component with hardener) and custom logos.

My weight aim is as follows (with 7kg stock weight)

Screenshot 2024-12-02 115134.png (16.78 KiB) Viewed 1488 times

Currently I already removed some of the paint and the frame is at 800gr.

Will update on this thread once I make progress

[TT02]

Cool project, looking forward to your progress.

The finished build will be perfect vehicle for the tyrolean mountain area. which i know very well, i rode, a lot there, The Kühtai-climb is one of my standard-courses.

[HiModular]

Cool project, looking forward to your progress.

The finished build will be perfect vehicle for the tyrolean mountain area. which i know very well, i rode, a lot there, The Kühtai-climb is one of my standard-courses.

Yeah Kühtai Climb is a classic around here. I recently did the Bergkaiser Race up Kühtai and I wished I had the finished supersixevo then

Anyways.. Current status is that I finished to sand down the fork and applied some primer weighing in at 316gr.

By feeling I would say I already sanded down the frame at least 6 to 7 hours and still no end in sight. Currently sitting at 775gr.

Looking forward on receiving the carbon fiber sheets and the resin so I can start with the top tube repair.
Would be great if I could be around the original weight (840gr) with the Carbon Repair and new paint on.

Also received the stencils to spray paint the logos on the frame once finished. I am thinking about placing the supersixevo on the side of the frame (where the cannondale usually sits).

The High Modulus Font should be on the top tube and maybe the High Modulus logo (Particle Logo) will be the front logo on the steerer tube.
Not sure yet about the final placement.
Logo color might end up to be neon green and the frame and fork will be "signal black" which is a very nice black matt finish.

Will update once the Carbon repair is finished.

[lock40Nm]

There is all what you need. https://www.easycomposites.eu/

[HiModular]

So I finished the carbon repair, filler and 2K black matt paintjob today.
The paintjob is a 2 component with hardener black matt color RAL# 9004.

I used 12K carbon and some unidirectional to fix the frame.

After three layers I baked the carbon / epoxy mix in the oven after compressing it.

I also used Infrared lamps for postcuring.

Then I started to to the filler work on the frame. Fixing most of the bumps.
The original cannondale paint was very hard to get off, especially the clear coat was brittle in some parts which made sanding an overall nightmare (like always).
However with the filler I made every surface look good enough for the black paintjob.

After painting the frame and fork outside I quickly moved everything indoors (its winter in austria) and started to turn up the heater inside my apartment as well as spotcuring with infrared.

If everything goes as planned I will be able to do the stencil graphics on sunday.
This means I can start building up the bike next week (I got alle the parts except the carbon wheelset for now).

Will keep you posted

[TT02]

.......

Will keep you posted

Please do so! Already enarmored in this bike! The paintjob looks amazing, and the repair-work seems tremendously well done.

[HiModular]

So today was stencil / masking day - finally spraying on all of the logos.
Everything went good so far - will have to check the final result later when I will peel off the stencil.

[HiModular]

And this is what the logos look like

Slowly coming together..

[bmrk]

Amazing project, congrats!

How many layers of each type (uni, 12k) and which orientation have you used for the top tube?

How much coverage to each side of the crack?

Thanks!

[HiModular]

Amazing project, congrats!

How many layers of each type (uni, 12k) and which orientation have you used for the top tube?

How much coverage to each side of the crack?

Thanks!

Hey there. I covered around 2-3 inches (6cm) over the damaged area to have enough bonding on good structural material.
I used 3 layers of the very thing 12k and let it level out to 1 layer on the sides (so more layers in the middle).
Then I baked the epoxy and started sanding.
Did some coin knock tests and it sounded good.
however I still was not happy with the overall wall thickness of the carbon and so I decided to use some uni carbon again around the damaged area (2 layers).
I have to say that I used the layers in a "wrap around" fashion (I usually don't trust spot repairs).
Then I sanded it down again and used some polyester filler to even out the small cosmetic spots.

For the orientation of the 12k I just layed in on straight towards the top tube.
For the uni I was laying it into the direction of the wrapping (so 90 degress to the side).

The repaired spot will for sure have less compliance because its just more material - but I don't think it will make any difference in riding feel.
If we look at the structural analysis we see that there is not a lot of load in this part of the frame - so the goal is just to stop it from cracking.

I think as long as you sand down to bare carbon and use some good quality epoxy and carbon fibre, make sure that you wrap around the damaged area and have it compressed down (either with a special shrinking tape or with electrical tape that you put on with high force) - you will not have any issues.
I also like to bake and infrared heat my epoxy / carbon as well as my 2 component paint jobs.
I saw many studies showing that pre and postcuring heat and IR treatment will significantly increase the overall strength.

[bmrk]

Amazing project, congrats!

How many layers of each type (uni, 12k) and which orientation have you used for the top tube?

How much coverage to each side of the crack?

Thanks!

Hey there. I covered around 2-3 inches (6cm) over the damaged area to have enough bonding on good structural material.
I used 3 layers of the very thing 12k and let it level out to 1 layer on the sides (so more layers in the middle).
Then I baked the epoxy and started sanding.
Did some coin knock tests and it sounded good.
however I still was not happy with the overall wall thickness of the carbon and so I decided to use some uni carbon again around the damaged area (2 layers).
I have to say that I used the layers in a "wrap around" fashion (I usually don't trust spot repairs).
Then I sanded it down again and used some polyester filler to even out the small cosmetic spots.

For the orientation of the 12k I just layed in on straight towards the top tube.
For the uni I was laying it into the direction of the wrapping (so 90 degress to the side).

The repaired spot will for sure have less compliance because its just more material - but I don't think it will make any difference in riding feel.
If we look at the structural analysis we see that there is not a lot of load in this part of the frame - so the goal is just to stop it from cracking.

I think as long as you sand down to bare carbon and use some good quality epoxy and carbon fibre, make sure that you wrap around the damaged area and have it compressed down (either with a special shrinking tape or with electrical tape that you put on with high force) - you will not have any issues.
I also like to bake and infrared heat my epoxy / carbon as well as my 2 component paint jobs.
I saw many studies showing that pre and postcuring heat and IR treatment will significantly increase the overall strength.

Thanks for the comprehensive answer!

[HiModular]

Today I finished cable routing, brakes, derailleur and the cockpit.
Sadly I will have to wait for the wheels to arrive which might take some time still.

So far I am really happy with how the design concept that I had in my head is playing out in real life.
Can't wait for the final weigh in..

Also pretty stoked about the seat / seatpost combination weighing in at under 200gr!
Gelu Seat and AliExpress Carbon Seatpost (shortened).

[Aeo]

If you want to save even more on pedals, XPEDO SONIK SPD-SL are 188 grams in the Ti version

[HiModular]

If you want to save even more on pedals, XPEDO SONIK SPD-SL are 188 grams in the Ti version

Thanks for the recommendation! I will have to go with my Favero Assioma Duo's because I need the Watt Meter.
But will look into your pedals

[HiModular]

Received my Carbon Wheels now.

Setup is:
Carbon Spokes
Clincher with TPU Tubes (Cyclami 30g)
30mm deep
Continental GP5000 28mm

Front weight (493gr)

Rear weight (626gr)

Bike weight without pedals ( 5,475 kg )

After adding pedals I will add another 220 gr to the bike which brings me to my total weight of
5,695 kg

Pretty happy with the results!