Trek 5500 Rebuild

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KB
Posts: 3967
Joined: Mon Jan 12, 2004 12:32 pm
Location: HULL UK

by KB

This is a proper ww project. Love what you're doing here.

by Weenie


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Kastrup
Posts: 570
Joined: Sun Dec 05, 2010 12:00 pm
Location: Aarhus, Denmark

by Kastrup

A friend of mine is riding the exact same frame, might try to convince him to do the same! :) Or at least let me do it!
"Stay cool and try to survive" A. Klier to the other members of the Garmin classics squad the night before P-R.

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craigtheduck
Posts: 44
Joined: Sun Jan 16, 2011 7:06 pm
Location: UK

by craigtheduck

Thanks everyone.

A little update on progress:

I finally got the bottom bracket out and have weighed the frame in its full nude form, weight came in at 1050g!!
Obviously a little weight will be added with the new cable stops, clearcoat and decals, but for a 14yr old frame its pretty good.
The fork is still annoying me, weighing in at 503g, but hey you cant win them all and maybe I will upgrade this in the near future. On the bright side the expander came in at 9g which was a surprise.

Will hopefully pick up some cable stops later today and them i can get on with adding decals and clear-coating.

I have also been working on the seatpost.

Original form.

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Out comes the hacksaw, Chop chop

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Some work with the dremel, may lay up some additional carbon fibre to give a little extra support.

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Still needs work, cutting out more material for the U-bit to sit securely. As you can see I have left part of the aluminium in so as to help spread the load of the U-part and will use part of a cork and some copydex(latex glue) to stop water getting in.

Current weight is a touch over 100g, I was hoping for around 150g complete but its looking like it will come out lighter :D .
I still need to drill the hole for the 'bar' and manufacture the bar and yokes and pick up some ti bolts. I think i will also layup some more CF around the top/where the holes are for the bar, just to make sure.

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Frankie - B
Admin - In the industry
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Joined: Mon Jun 02, 2003 8:17 am
Location: Drenthe, Holland

by Frankie - B

Woohoo! This is what WW is about!
'Tape was made to wrap your GF's gifts, NOT hold a freakin tire on.'
If you want to see 'meh' content of me and my bike you can follow my life in pictures here!

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craigtheduck
Posts: 44
Joined: Sun Jan 16, 2011 7:06 pm
Location: UK

by craigtheduck

Look what I picked up on Friday


Very unexciting, Cable stops courtesy of argos cycles in bristol

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Slightly more exciting, new decals. They aren't blue, that's just the backing. Just a white outline of trek so the carbon can be seen through the centre of the text

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Got these done in visual impact on bath road in bristol. Very quick service, I only went in for a quote :shock:

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craigtheduck
Posts: 44
Joined: Sun Jan 16, 2011 7:06 pm
Location: UK

by craigtheduck

Just a little update on progress.

The cable stops are now glued to the frame and are drying as I type, I plan to apply the decals and get the clear coating done within the week :D . Then I need to find some brakes, get down the workshop to finish the seatpost parts, Build up the wheels and put it all together. Simples :shock:

I am also currently making a top cap out of some carbon fibre, It was a rushed job, so it may well turn out rubbish but we shall see.

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craigtheduck
Posts: 44
Joined: Sun Jan 16, 2011 7:06 pm
Location: UK

by craigtheduck

A little something from the weekend.

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I think I will call it wasserogre.
Yes its light but trust me this thing is UGLY looking, and dont worry btp/tune, I know this looks a bit like your cages but im not planning on selling it and even if I did I wouldn't buy it as it looks like its been made by a child.

Seems to function well enough, I can imagine bottles getting stuck in being more of a problem than bottles falling out. And the best bit... It was virtually free.

If anyone is interested in how I made such a monstrosity it was as follows. I am a mechanical engineer and have studied composites design and manufacture, so I know this isnt pretty, using a mould would have given much better results but the more time I spend making moulds the less time riding.

1. Wrap bottle in clingfilm, glue on bolts in correct position
2. Lay up woven reinforcement in bolt area
3. wrap UD (as I had some for free, woven/1 layer woven probably better) around bottle
4. leave to cure 90%
5. Remove from bottle, peal off clingfilm
6. use dremel to make it look a little less scruffy and fix holes

The 'top-cap' I made the other day in a flurry of "ah i have so much resin left I must make something with it before it sets" Is only 2g so I'm questioning if it will be strong enough. I will see how it works out but currently its finish is poor and roundness is questionable, I may tension the headset with another top-cap, do up the stem then use this to hold it all down after, It could then be used on a ride if the headset ever comes lose whist riding.

And just in case anyone is interested the parts that were removed from the frame all weighed 100g exactly!

KB
Posts: 3967
Joined: Mon Jan 12, 2004 12:32 pm
Location: HULL UK

by KB

Great work, keep it coming.

BmanX
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Joined: Thu Nov 10, 2005 5:31 pm

by BmanX

I know something that will be coming from North America that will be shipping today that will lighten the build a fair bit. Should allow a ~200g drop in weight.
BIG DADDY B FLOW
AERO & LIGHT is RIGHT for 2 decades

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craigtheduck
Posts: 44
Joined: Sun Jan 16, 2011 7:06 pm
Location: UK

by craigtheduck

North America is currently my favourite place!
Things are getting exciting now, the frame is done, I'm now just waiting on the final components.

Here is a teaser.

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I have also been down the workshop today and have made the parts for the seatpost, final weight is 142g so a saving of 110g over the original! I hope to get some Ti bolts in the near future which should save a further 8g.

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I also just weighed the saddle, 311g :unbelievable: I think I may need to do a sneaky swap at some point.

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majklnajt
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Joined: Thu Apr 10, 2008 6:40 pm
Location: Lenart, Slovenia EUROPE

by majklnajt

You can buy mine Prologo Scratch Nack, 164 grams ;)

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craigtheduck
Posts: 44
Joined: Sun Jan 16, 2011 7:06 pm
Location: UK

by craigtheduck

You must be a god with the ladies if you can get them to sit on something called scratch nack :wink:

Whist waiting for the post man I have built up a not so weightweenie but very budgetweenie 15.2kg tandem this weekend, a project I have been wanting to do for ages. We went for a ride today and after 5mins i was told "I am never riding a bike again". Lets hope the finished trek changes her mind.

Does anyone want to buy a tandem? I'm only joking I had far to much fun to sell it yet

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majklnajt
Posts: 3637
Joined: Thu Apr 10, 2008 6:40 pm
Location: Lenart, Slovenia EUROPE

by majklnajt

Sorry, didnt realize the bike is for your lady!! :mrgreen:

SDP
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Joined: Tue May 04, 2004 1:23 pm
Location: uk
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by SDP

good saddle if your lady likes the JETT is the glamour Aspide TI - about 180gm IIRC ?
one on my wifes bike & she loves it ..

by Weenie


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Great Prices ✓    Broad Selection ✓    Worldwide Delivery ✓

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Timo
Posts: 1380
Joined: Mon Jan 24, 2005 12:10 am
Location: Amsterdam, the Netherlands

by Timo

To quote Montey Python: GET ON WITH IT!

We demand opdates and photos 8)
And if I ever meet an aardvark, I'm going to step on its damn protruding nasal implement until it couldn't suck up an insect if its life depended on it.

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