Here's my new build from this spring
My goal was to build a decent WW machine with my limited mechanic 's budget.
I started with a 2005 61cm Tarmac Pro frame .
It came painted in a gorgeous red color, but as I looked closer I could see the paint was abundant to the point where it had waves in it due to too much thickness, as I expected the frame came in at a porky 1584 grams with no seat collar, including bearings.
I was convinced I could do something about it...
I took on the project for the majority of my spare time last winter.
Most of it was spent stripping and refinishing the frame, an ordeal I don't want to go through again:
The frame had many productions defects in the cosmetic weave, to top it off all the junctions of the tubes to lugs areas where filled with mastic filler * ie: Bondo * .
The paint was a complete nightmare to remove, it might have been epoxy based, I have never seen such hard paint.
Due to the paint's thickness, wet sanding was next to useless, the only thing that could be done was to use a commercial paint stripper.
I selected Star 10 Phase 1 semi-paste
gel because of it's composite friendly nature, still it took over 45 minutes of " cook " time at each application and they where quite a few, then a Swix metal scraper ( made to scrape skis ) was used to remove it as soon as the paint had softened to a degree,but it was still difficult to remove even with a metal scraper .
After the paint was stripped, the mastic was then scraped off and wet sanding was used to finish the job.
All this took over two months,the frame was a complete mess due to poor finishing from factory. Many divots in the CF outer layer had to be filled once the heavy useless mastic was removed.
I chose to fill the gaps with a industrial grade of cyanoacrylate glue , similar to Krazy Glue but much stronger and durable , this took a month one small layer applied then sanding, over and over.
The frame, nude and with all the divots filled, ready to paint was 1361 grams. That's a 223 gram saving.
Because the cosmetic outer weave and may defects in it I was forced to use paint instead of just clear coating the frame.
All that you see here is done with a spray can, fade out and all .
The Specialized down tube graphic was done with a stencil I made out of a Specialized FSR series sticker set I bought on ebay.
I chose to use the same black color of the rest of the frame for the lettering.
The S logos are sticker ghost; paint over stickers and then removed to show the CF under.
The clear coat was treated to #1000 & #2000 grit wet sand paper and Meguiars Scratch X
polish was used to complete the mirror finish .
Final weight of frame with no seat collar is 1384 grams complete with all alu bolts , alu down tube adjusters,headset bearings and clear polyurethane chain stay protector .
That's a ~20 gram paint finish,not bad compared to the 200gr + factory one !
The build list goes as follows:
Frame:Specialized Tarmac Pro (custom paint) 61 cm 1384 g including bearings
Fork: Specialized S-Works 1 1/8" 321 g (cut )
Headset : OEM Specialized FSA Integrated 1 1/8" 19 g
Headset Spacers : FSA Carbon 15 mm, Including Time Top cap 12gr
Stem: KCNC SC Lite 120 mm ±6° 113 g
Handlebar: Syntace Racelite Carbon 31.8 44 cm OO (L) 181 g
Bar Tape: Bontrager Race Lite & Rav-X Plugs 33 g
Seatpost: m2racer Carbon 27.2/300 mm 80 g
Saddle: Specialized Toupe 143 mm 165 g with modified tip
Seatpost Clamp : Specialized Tarmac (tuned + ti bolt) 34 g
Brakes: Zero Gravity 0G-06 Ti BBB Triple Compound Pads 182 g
Shift/Brakel Levers: Shimano Dura-Ace ST-7800(Ti bolts&nuts) 410 g
Front Derailleur: Shimano Dura-Ace FD-7800-BM(Alu screws) 31.8 mm 78 g
Rear Derailleur: Shimano Dura-Ace RD-7800-SS (fully tuned ) 148 g
Bottom Bracket: American Classic ISIS Road 68x108 mm 141 g
Crank Set : FSA Carbon Pro Elite Compact + Bolts 175 mm 36/50 548 g
Pedals: m2racer ORB II Ti 99 g
Chain: KMC X10 SL 100 links 222 g
Cassettes:KCNC TI,SC,7075 11-23 10-speed 116 g
Skewers: m2racer Ti QR skewers 40 g
Wheels: Custom AmClassic Micro/Ultra Light, Alex R400 Rims, DT Aerolite, DT Prolock Alu nipples. 20/24 holes 1280 g
Rim: Tape Rox SuperDutE ( for two rims ) 8 g
Inner Tubes : Continental Race 28 Supersonic S36 700x18-25C (for two) 102gr
Tires: Continental Grand Prix Supersonic 20-622 ( for two) 284 g
Brake Cables : Jagwire Ripcord & IoDuPont Powercordz 65 g
Gears Jagwire Ripcord & IoDuPont Powercordz 58 g
Bottle Cage(s) RavX Beta X 16 g
Final Weight :6134 grams
The bike rides fantastic,the paint stripping did not affect the ride or stiffness of the frame at all ; it feels just like all the other Tarmacs of the same size I have ridden.
The fit is perfect and I love the Tarmac geometry, fast yet stable.
Overall I achieved my goal, the bike was built up because I got a great deal on the frame.
The wheel did not cost too much, got a deal on the hubs, the DT Aerolite spokes being the most expensive part.
Stem and cassette came from Fairwheel Bikes ,thank you Jason.
I got the gears working almost satisfactory on the KCNC cassette by taking out any slack in the cable system and shimming the Dura Ace derailleur pivots to take any play out, the upper pulley was changed to an XT and I filed the ceramic bushing to remove the float.
The Bontrager Race tape was chosen not only because of it's low weight but it's slimness ,it really makes the Syntace Racelight bar come alive ,all positions can be used with it unlike thicker tape that limited me from getting a good grab on the ergo top of the bar
After ~1400km :
The AC BB gave me some creaking at first but I then replaced the Loctite nickel anti seize I had in the cups and shims with the better quality Kleen Flo nickel paste.
The Powercordz have been flawless,the only problem occurring when the cable dried up at the BB cable guide , I then re-applied some Finish line Stanchion Lube that I used to lube the cables ,now it's running fine.
Sorry for the long post ; it was a very long project to get together,lots of small juicy details, lol