OK, I tried it.
The goal was to file down the "steps" at the bottom of the freehub body to create 1mm of additional room so the 11T cog in the 9000 cassette can engage on the splines.
This is the first time I filed or drilled anything in a very long time... so I didn't know what to expect.
The aluminum in the 182 freehub body appeared to be soft, so the first stroke took out some anodization without difficulty. I went on for another 15 minutes, and took out maybe 0.7mm of material, which allowed the 11T cog to engage not by too much. I wonder whether hard sprinting would strip the aluminum splines. Fortunately I torqued down the lock ring and the cassette was able to go down even further (by probably 0.2mm) so that allowed the lock ring to wind maybe another half circle.
It looks like if I file off another 0.3mm, then the 11T would sit a bit more securely on the splines, which would alleviate my worries about stripping the splines. The filed surface doesn't look very pretty so I will try to clean it up a bit tomorrow as well. That being said, the "steps" weren't very thick to begin with (2mm?), so I needed at least 1mm left to push against the largest cog holder.
Now the 11 DA cassette is fully installed on the freehub body, but the lock ring is awefully close to the overlock nut, so I was worried the lock ring or the chain in the 11T would touch the dropout. Fortunately the right dropout is slightly curved at the opening, in a way that the lockring won't touch the dropout. I wonder if this will be true for my ti frame which has a dead flat dropout. On the largest cog, the chain seems to be quite a few mm's clear of the spokes, so no problem there whatsoever. On the smallest cog, the chain in 11T was also clear of the dropout by maybe 2mm.
A slight twist is that my carbon bike with DA9000 was stripped, so instead I put the wheel on my alu bike w/ Chorus. But no worries, shifting was flawless between the 9000 cassette and the 11sp Chorus drivetrain, even with the thicker Campy chain (I had tried Campy cassette on a 9000 drivetrain a couple of weeks ago and it was working fine as well). So there you have it ---- 10 speed Zipp hub modified to take 11 speed DA 9000 cassette running with an otherwise 11 speed Campy drivetrain.
I should do this stuff more often. LOL
Am i completely crazy?
Crazy like a FOX!
Just watch out for the chain clearance as you mentioned....and of course the derailleur when you shift to the last cog on the cassette. Let us know what happens.
Fast falcons: http://www.youtube.com/watch?v=j3mTPEuFcWk
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