Keyne's DH Comp Build - now with liquid cooled HX35! :)

[Doctorbass]

I sure hope you don't mind if I save some pics of those dropouts. Elegantly simple. I love it.

I have some more pics for you right here :http://endless-sphere.com/forums/viewtopic.php?f=3&t=18473&start=60

Doc

[torker]

Thanks Doc ! Is it just me or are some pics messed up? I know we lost a bunch( I noticed in the Mag max thread) But now I get a lot of yours that are either half missing or looks like mixed pixels on half ?? Just want to see if it is just me? Don't mean to hijack

[keyne]

Next Step : Disc Brake adaptor

So I want to use a 9 Speed freewheel which means there is not a lot of space for the disc brake. So I gained about 6mm by having a disc brake adaptor machined like this:

Modified disc brake adaptor

brake_adaptor_back.jpg (103.35 KiB) Viewed 1375 times

In retrospect I should have used on of the Avid ones as they are much stronger looking, but I'll see how this one holds up.

Shimano rear brake adaptor mod

brake_adaptor.jpg (215.44 KiB) Viewed 1375 times

Here's how it fits on the dropout:

dropout plus brake adaptor

dropout_plus_brake_adaptor.jpg (168.71 KiB) Viewed 1363 times

There is only 3mm of thread left at the back of the brake adaptor (the front of the brake adaptor and the dropout are unthreaded holes) so there is not much there, but it seems to be ok.

[keyne]

I forgot to mention that the reason I've been so careful with making the dropouts is that I have one of the old x5305 motors that have a 12mm diameter axle, not the newer 14mm that most big motors have. As you can imagine 12mm diameter with 10mm between flats doesn't leave much room for error! If I was just using a normal 14mm diameter axle I probably wouldn't have bothered with making them clamp nicely (but now that it's done I'm pretty stoked with them!)

[keyne]

While I had the frame apart, I bought a bearing replacement set of Voicecoils who had it left over from his DH team build.
Suspension runs really smooth now!

Replacement Bearings for Giant DH Comp

replacement_bearings.jpg (143.33 KiB) Viewed 1331 times

[keyne]

Had a chance to do some painting through the week and on the weekend. Swing arm, frame, forks, motor and controller.

Frame and swing arm painted

Painted Forks

painted_forks.jpg (161.24 KiB) Viewed 1304 times

painted motor covers

motor_panels.jpg (244.24 KiB) Viewed 1304 times

painted lyen controller

controller_painted.jpg (146.67 KiB) Viewed 1304 times

lyen_cont_bot.jpg (124.05 KiB) Viewed 1316 times

left hand dropout post painting

lh_dropout_paint.jpg (120.83 KiB) Viewed 1316 times

right hand dropout post painting

rh_dropout_paint.jpg (118.75 KiB) Viewed 1316 times

[voicecoils]

While I had the frame apart, I bought a bearing replacement set of Voicecoils who had it left over from his DH team build.
Suspension runs really smooth now!

Nice!!! I'm stoked to see them getting used

[voicecoils]

Had a chance to do some painting through the week and on the weekend. Swing arm, frame, forks, motor and controller.

frame_spray.jpg

Looking good.

Did you see a serial number anywhere on the frame when you tore it down?

[keyne]

Hmm.. I'm pretty sure there was a serial number under the bottom bracket but I didn't really pay attention. Why do you ask?

[Mark_A_W]

Hey Keyne

Does your frame have a serial number on it? If so, where is it?

I can't find one on mine and the insurance company needs it for me to add it to the household contents insurance ($50 for $2000, insured against theft away from the home).

My bike has the controller and battery box stuck to it, so I can't say for sure that it's missing completely, but I sure can't find the serial number

[Mark_A_W]

Hmm.. I'm pretty sure there was a serial number under the bottom bracket but I didn't really pay attention. Why do you ask?

Ooops. I just read the last two posts.

He's asking coz I asked him about the serial. I got my frame from Voicecoils and he used to have a spare, but it's sold.


Need it for insurance, and it's not in the normal spot on my frame - certainly not under the bottom bracket.

[keyne]

I think I just remembered where it is/was and that's not good news for you. I'm pretty sure it was actually on the left rear drop-out by the disc brake mount (between the holes) I chopped it off with an angle grinder so can't check. But I'm pretty sure it was there.

I'm not in the same place as the bike at the moment, so can't check for about a week. Sorry.

[Mark_A_W]

Well, I sure didn't look there!

That bit of my bike is still more or less intact. I just had a look - I can see a couple of numbers, but then the torque arm plate covers it.


I have to pull the motor out to replace the freewheel this weekend, so I can get the number then.


Sweet - that clue helped me out heaps


Thanks

Mark

[Mark_A_W]

You can see yours here:

[torker]

That bike is looking really good. I sure hope my FSR turns out good. Got my rear tire and tube today and...My spokes are on the way

[jlustig83]

Those are the most sophisticated torque arms ive ever seen You are my idol

[keyne]

Thanks jlustig83, to be honest most of the work was done by doctorbass I just made a few modifications to suit my needs. If I was doing it again I'd do it a bit differently. They are quite over engineered and weigh almost 600g for the pair!

[keyne]

You can see yours here:

Ha! I spent about 15mins looking for pics on the web to help you and it was there in my thread the whole time!

[keyne]

There was something funny going on with the handlebars on the DH Comp, they were super wide (780mm!) and amazingly strong. I finally worked out that they are actually Motocross bars (from Aero Racing) and weigh 650g!

I was wanting to swap them with some black ones anyway, so I just bought some Easton DH bars and saved 350g on the bike! Stoked!

[keyne]

I want to get two 24x3.0 Duro Razorbacks for this build (lightest 3" wide offroad tyre I can find) but I can't find anywhere to buy it that will send to New Zealand. They are on Ebay, but don't ship overseas. Does anyone know an alternative source or is anyone willing to purchase them for me and send them on?

http://cgi.ebay.com/Mountain-Tire-24x3-00-Duro-Razorback-SALE-we-are-nuts_W0QQitemZ280558566948QQcategoryZ27954QQcmdZViewItemQQ_trksidZp5197.m7QQ_trkparmsZalgo%3DLVI%26itu%3DUCI%26otn%3D3%26po%3DLVI%26ps%3D63%26clkid%3D7911932003719746177

Duro Razorback 24" x 3.0

!BzuCelgBGk~$(KGrHqMOKj0EwrjCSt(eBM(TltLRD!~~_2.JPG (6.45 KiB) Viewed 800 times

[voicecoils]

I want to get two 24x3.0 Duro Razorbacks for this build (lightest 3" wide offroad tyre I can find) but I can't find anywhere to buy it that will send to New Zealand. They are on Ebay, but don't ship overseas. Does anyone know an alternative source or is anyone willing to purchase them for me and send them on?

Naturally, I have a new pair I can send you

They don't fold easily though so shipping might be pricey!

[Mark_A_W]

I pulled my torque arm off and got the serial number on my frame.

Thanks for the help guys.

[keyne]

wow! Awesome voicecoils, please let me know how much you want for them. Where did you get them from?

[Doctorbass]

Hey.. I have something that might help any DH comp owners

Bison_69, a friend of mine and member of E-S made that for us!;

Doc

[full-throttle]

Nice build!

How did you balance the bike in the pics? Can't see any strings..