Here is my latest build. The Motoped is still moving forward. But, I wanted to try out the new frame jig. So, I decided to start on a build I began planning over the summer.
For the last 2 years I have been watching eBay for a decent downhill frame for a low cost. This is an Intense frame built for Haro. It was in rough shape, dented, and slightly bent. So, I got it for a song. The damage means nothing to me because I am only using the suspension. Even if the suspension is bent, I can repair that with my TIG and my jig.
This build is basically an extensive upgrade to my Cannondale Hooligan. The Hooligan was built as a "Quickie" build. I have about 10 hours in that build, total. So, it was limited to what could be accomplished in a short period of time. This build will use all the components from my Hooligan.
What changes are being made to the bike beyond the new frame with rear suspension?
---The wheelbase is increasing 2 and 1/4 inches from the Hooligan's 41 inches to 43.25 inches. This is being done to increase stability at speed (45mph) and reduce wheelie tendency.
---The battery capacity is increasing from 25 ah (12S) to 40ah. That looks to be the most I can fit in this relatively small frame without taking extreme measures.
---The head tube is replaceable and the front ride height is adjustable 1/2 inch vertically. There are a number of reasons I have decided to go in this direction with the head tube. More on that later.......
---The rear suspension travel is being reduced from 8 inches to around 4.5 inches (this is a road bike after all) using a shorter travel shock I had laying around the shop.
---The bottom bracket is raised 1.4 inches to provide crank clearance with some suspension squat.
The box is 6016 and is 1/8 inch thick. I wanted the frame to be as strong as possible and I needed some thickness to tap threads into. It measures 6 inches wide. This was the widest that was practical and aesthetic. It will have removable G10 side covers. It will most likely be flat black with some subtle white lettering.
This bike will be setup with a 5 turn 3220 with delta/wye switching. Gearing is 26mph in wye and 45 in delta.
The Hooligan already handles very well. It should be improved tremendously. The weight will better distributed and, with only 25ah, it is too light. The added 15ah of battery capacity will increase stability by adding weight. Also, the bike is really too wheelie prone right now. The new suspended bike should be much more controllable. This is a good thing because this bike is being built to accept two 3220s when I get bored with it as it is.
I hope to have the box done this weekend. I will be out of town for 5 days over Christmas, though. So, the build will stall for a while at that point.
1% of the world's population can think "Outside the box". The rest are firmly stuck within the box. Where are you?