Heres a quick pic of how my Y Foil arrived from the States to UK. Well used and obviously set up as a TT complete with disconnected brifters and bar end shifters only.
Full Dura Ace which was nice.
I almost s@@t a lung getting it out of the box, it weighed in at a hefty 10.23kilo
Most parts came off easily until time to remove front forks. I tried every trick in the book, heating, WD40 upside down overnight, leverage with bars, googled it, Youtube'd it. Nothing worked, steel steerer tube and alloy stem had become one after years of being dripped in sweat. Eventually brute force was the only option.
Finally stripped down the frame weighs 1.851kilo. Still quite hefty, these things were built to last they are actually a hugely strong frame. When riding its almost like having two frames beneath you, whilst sitting you are cushioned from road vibration and bumps by the slight flex offered by that beam. Stand up and push and you instantly feel rigid feedback, the Bottom bracket area and entire rear triangle is renowned for being immensely strong.
Removing paint brought weight down to a surprising 1.652 kilo, still no lightweight.
Bottle cage holder made of cast alloy 44g.. gone
Front mech hanger 46g.. gone. I have some plans for a replacement.
Original English screw in Bottom bracket 88g.. gone. This didn't want to come out easily, I also have plans for this area of the build.
Rear dropouts 131g .. surely not.. yep gone.
Having removed bottle cage holder, front mech and also the rear brake mounting stud gives an opportunity to further reduce weight and modify that whole frame area. Fortunately Treks original frame construction method aids this. Well it leans in the right direction to help with modification at least.
These original 3D conception drawings from way back in the early days of this frame design show how it all went together. And what goes together can also come apart again.
Time to build a 'new' lightweight upper carbon seat stay section complete with moulded in front mech hanger.
First stage is to shape a mech hanger
Stick it in place and create a plug ready to form a mould.
Carbon part straight from the mould ready to clean up
Initial dropout plug
Straight from the mould
Dropouts will become an integral part of the rear forks
All new PF30 carbon BB ready for final bonding
Heres an indication of where its heading. That hideous piece of metal tube bonded to the BB area is temporary, its my point of reference for the front mech hanger and will be removed once everything is in place.
A side view mockup with proposed swanky new SRAM red GXP crankset and Di2 mech
To be continued.