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PostPosted: Thu Mar 31, 2016 12:29 pm 
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Location: Katwijk
It was one of those days, I looked at my favorite mountainbike (Cannondale F600), and dreamed about a new color for the frame. I always loved Metallic paint on cars so that was my main goal. An other item that was on my wish list was a Handlebar/Stem combo.

Because you can’t get a handlebar/stem combo for Cannondale Headshok I needed to make one myself. I milled a stem I had laying around to the dimensions I wanted (31,8mm diameter and 100mm length) and had a nice light handlebar laying around (700mm width). Brought that to a local aluminium welder and pict it up one day later. After some putty and sanding the end result was very good looking (as I may say so).

ImageDSC_0187 by Ronald vdBoon, on Flickr
ImageDSC_0188 by Ronald vdBoon, on Flickr
ImageDSC_0213(2) by Ronald vdBoon, on Flickr
ImageDSC_0234 by Ronald vdBoon, on Flickr
ImageDSC_0285 by Ronald vdBoon, on Flickr
ImageDSC_0288 by Ronald vdBoon, on Flickr

Than it was time for some spary painting and polishing. I wanted the frame, headshok fork, handlebar/stem combo and seatpost in the same color. The bicycle brand Speedvagen was a huge inspiration for this project to. As I already got an limited edition XTR polished rear derailleur, I also polished my crankset, magura brakes and some other parts.

ImageDSC_0308 by Ronald vdBoon, on Flickr

Took my time on this one as I screwed up lots of other spray paint projects. But this paintjob came out really good. The stickers I made en designed myself. I’m privileged to have a professional sticker printer and cutter at my work so these are of pro quality.

ImageDSC_0316 by Ronald vdBoon, on Flickr

And finaly here is the end result which I´m really proud of:
ImageDSC_0418 by Ronald vdBoon, on Flickr
ImageDSC_0367 by Ronald vdBoon, on Flickr
ImageDSC_0363 by Ronald vdBoon, on Flickr
ImageDSC_0361 by Ronald vdBoon, on Flickr
ImageDSC_0358 by Ronald vdBoon, on Flickr
ImageDSC_0353 by Ronald vdBoon, on Flickr
ImageDSC_0340 by Ronald vdBoon, on Flickr

Ronald

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Cannondale F600 tuned (9kg)


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PostPosted: Thu Mar 31, 2016 1:08 pm 
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Location: Los Angeles / Glendale, California
WOW!!!

That's one amazing second post on the forum! Stunning work with a classic!!
Super impressed.

How is the stiffness of your stem/bar combo?

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PostPosted: Thu Mar 31, 2016 1:30 pm 
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Posts: 548
Location: Northamptonshire UK
Very cool!! I'd like to see it with some xtr v brakes instead though, I never liked those hs33s.


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PostPosted: Thu Mar 31, 2016 1:40 pm 
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I love it! It looks just great.

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PostPosted: Fri Apr 01, 2016 12:26 pm 
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Location: Katwijk
prendrefeu wrote:
WOW!!!

That's one amazing second post on the forum! Stunning work with a classic!!
Super impressed.

How is the stiffness of your stem/bar combo?


Thanks, the combo is just as strong as a normal handlebar stem (bolted) combi.
Klein bikes made these kind of handlebars in the past to.

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Cannondale F600 tuned (9kg)


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PostPosted: Fri Apr 01, 2016 12:28 pm 
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Location: Katwijk
burglarboycie wrote:
Very cool!! I'd like to see it with some xtr v brakes instead though, I never liked those hs33s.


I would love that to, that will reduce the weught at least with 200grams.
I rode XTR v-brakes and Hs33 brakes in the past, but the HS33 where stronger.

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Cannondale F600 tuned (9kg)


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PostPosted: Fri Apr 01, 2016 12:28 pm 
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kgt wrote:
I love it! It looks just great.

Thanks

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Cannondale F600 tuned (9kg)


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PostPosted: Fri Apr 01, 2016 12:56 pm 
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Location: Katwijk
Here is a weight list:
ImageCannondale F600 weight list by Ronald vdBoon, on Flickr

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Cannondale F600 tuned (9kg)


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PostPosted: Fri Jul 08, 2016 2:06 pm 
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Location: Katwijk
I grew up using Magura’s HS33 raceline. The where raced by my MTB hero’s Bart Brentjens and John Tomac. They looked cool and ad that time where the strongest brakes you could get. Now 17 years later I still use them, there timeless. Oke you now have disc-brakes, and I can see the advantages of using them. But I don’t have the money right know to switch to disc brakes.

One of the negative sides of using Magura’s HS33 is the weight penalty. And since I’m a weight wheenie and I design for a living, I gave myself the challenge to make the lightest Magura HS33 brakes.

Most Magura rim brake sets weigh around 750/800 grams. Which is a lot. I came to the conclusion that there were lots of places where weight can be dropped. So lets get started.

The Clamps.

On way of losing lots of weight was at the clamping area. The clamps are designed to be bolted on the V-Brake studs of MTB frames. There are 2 disadvantages,

The cylinders are mounted pretty far from the frame. You lose the direct braking power.
These studs weight around 8/9 grams each. So when these can be left out you save 36 grams.
An advantage of doing leaving the V-Brake studs is that I can mill all the extra material of the clamps you don’t need. And per clamp this is some serious weight loss. The standard clamps weigh 44 grams and you need 1 set for every cylinder. So that’s 176 grams. I milled it down to 22 grams per set.

Image20160610_114612 by Ronald vdBoon, on Flickr

I bolt the clamps down with a M8 bolt directly on the frame. It’s now tighter and I can feel I can brake a little more direct now. Especially on the rear. I polished the clamps and spray painted the cilinders in my frames colour.

Image20160708_070045 by Ronald vdBoon, on Flickr
Image20160708_070101 by Ronald vdBoon, on Flickr

Quick release

I made a though decision to leave out the Quick release. These weigh a lot (30 grams) and I really do not use it since I mostly never have a flat tyre. And If I have a flat tyre, the Latex or a plug will solve the problem. And of course the wheel can be taken out very easy if I have to. Just a little more work than normal but I take that for granted.

Boosters

Most boosters from magura are made of steel (weight 50 grams). So again here’s a nice weight improvement to be made. I made some carbon fiber ones weighing 10 grams each. And they are as strong as the steel ones.

Image20160708_070053 by Ronald vdBoon, on Flickr

Brake levers

Here is where I really went crazy/out of the box. I love clean looking handlebars. Now days with all the accessories you can put on your bars, it can look like spaghetti. Brake levers, shifters, dropper seat post lever and lock-out for your fork or rear-shok. Since I have a very simple setup (1x9speed) I only ride with one shifter and my lockout is on my Headshok itself.

So to reduce the weight of my levers, and make them look clean and cool (at least that what I think) I made the choice to remove the clamp which goes around the bars. I made the handle shorter and shaped it to my liking. The piston tensioning plate was made out of metal. So I made one of carbon. I don’t like the big red knob on top of the lever so I left it off and milled the nut down. Lastly I polished the cylinder and piston pushers. The lever was spray paint in the same colour as my bike. Originally the levers weigh around 95 grams, mine now weigh 65grams.

Image20160624_092453 by Ronald vdBoon, on Flickr
Image20160629_082801 by Ronald vdBoon, on Flickr
Image20160629_120002 by Ronald vdBoon, on Flickr
Image20160627_120130 by Ronald vdBoon, on Flickr

Then came the fun part, I glued them on my handlebar, using very strong epoxy 2 components glue. And to reinforce the brake levers I drilled a hole through the handlebar and bolted them straight on it. Solid as a rock. Then refinished the bolts and used epoxy to flatten the surface. And last but not least a fresh coat of paint + clear coat.

Image20160627_121225 by Ronald vdBoon, on Flickr
Image20160627_122439 by Ronald vdBoon, on Flickr
Image20160627_122449 by Ronald vdBoon, on Flickr
Image20160627_122457 by Ronald vdBoon, on Flickr
Image20160628_114424 by Ronald vdBoon, on Flickr
Image20160628_121121 by Ronald vdBoon, on Flickr
Image20160628_135144 by Ronald vdBoon, on Flickr
Image20160628_135158 by Ronald vdBoon, on Flickr
Image20160628_142506 by Ronald vdBoon, on Flickr
Image20160629_122413 by Ronald vdBoon, on Flickr


And here is the end result. What do you think?

Image20160629_122907 by Ronald vdBoon, on Flickr
Image20160629_125240 by Ronald vdBoon, on Flickr
Image20160629_125252 by Ronald vdBoon, on Flickr
Image20160708_070137 by Ronald vdBoon, on Flickr
Image20160708_070110 by Ronald vdBoon, on Flickr

Here’s a list of the weight differences before and after.

Imageweight by Ronald vdBoon, on Flickr

So that’s ±272 grams saved on just the brake set. So my Cannondale MTB is know at 9kg exactly.

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Test & Story Blog for all kind of cycling stuff

Cannondale F600 tuned (9kg)


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PostPosted: Fri Jul 08, 2016 2:52 pm 
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Joined: Sun Jun 18, 2006 10:29 am
Posts: 5363
Location: Athens, Greece
Respect !

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PostPosted: Fri Jul 08, 2016 3:09 pm 
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Joined: Tue Sep 22, 2009 1:29 pm
Posts: 795
Location: UK
Love your work!

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PostPosted: Fri Jul 08, 2016 7:21 pm 
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Location: Los Angeles / Glendale, California
This is wonderful!! Thank you for sharing your progress with this.

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PostPosted: Fri Jul 08, 2016 7:31 pm 
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Joined: Wed May 13, 2015 10:35 pm
Posts: 48
Removing the lever clamps is an amazing idea. It looks so good [THUMBS UP SIGN]

Sent from my UMI_SUPER using Tapatalk


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PostPosted: Fri Jul 08, 2016 8:58 pm 
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Joined: Thu Jan 22, 2015 6:58 pm
Posts: 548
Location: Northamptonshire UK
Great work!! Any more plans for modifications?


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PostPosted: Fri Jul 08, 2016 9:30 pm 
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Posts: 810
Location: Downtown Los Angeles, CA
Wow, the modifications look great. Awesome job and attention to detail.

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