Custom seatpost idea - Just stupid or so stupid it might just work?

[whyamihere]

I have a Merlin Inferno frame sitting in the garage. I rode it for a few months and then stopped for reasons related to the seatpost. The first issue is that its ears only accept round saddle rails, preventing me from using my preferred saddle. The ears are also somewhat loose (I had to shim the rails using a bit of coke can in order to stop the saddle rocking despite torqueing the bolt up to spec). I could have lived with these but the biggest issue is that it has a 20mm setback. I normally run inline posts, and I just couldn't deal with the setback. It can be flipped, but I don't think I'd be able to deal with -20mm setback either.

It's an aero post, so I can't just swap it out, so my idea is to create a custom seatpost. I have a spare Hylix seatpost similar to this one which I could use the fitting hardware from: https://www.ebay.co.uk/itm/302250200096. I would get a mould for the seatpost 3D printed so that it's around 2mm smaller in all dimensions and wrap it with carbon fibre. At the top of the post, I'd probably make an aluminium block which would be drilled through to fit the hardware from the Hylix post, with carbon wrapped over the block to hold it in place.

I know this won't be light, but the frame itself's not light. Alternatively, if anyone knows of anywhere I can get a pre-made post which would fit or anyone who does custom posts without spending an absolute fortune, let me know.

The 'right' answer here is probably to just buy a new frame, but I want to build this up as a spare parts bike without spending a lot on it.

[Lelandjt]

I was in the same dilema with a 2016 Fuji Transonic SL. First I bought a second stock seatpost so I wasn't cutting up the only seatpost that fits in my frame. I had a machine shop cut the top off, then cut a curve in the top to fit a cradle in and drill a hole through below for the cradle clamp rod. I took the cradle assembly from a round Hylix post I had. It would have worked perfectly if the machinist hadn't made a mistake then had to go shorter to fix his mistake, too short for the leg extension I like.

[whyamihere]

I was in the same dilema with a 2016 Fuji Transonic SL. First I bought a second stock seatpost so I wasn't cutting up the only seatpost that fits in my frame. I had a machine shop cut the top off, then cut a curve in the top to fit a cradle in and drill a hole through below for the cradle clamp rod. I took the cradle assembly from a round Hylix post I had. It would have worked perfectly if the machinist hadn't made a mistake then had to go shorter to fix his mistake, too short for the leg extension I like.

I thought about doing that but haven't been able to find a spare seatpost, and I don't want to risk destroying the stock one without a spare as that makes the frame useless.

[Lelandjt]

I was in the same dilema with a 2016 Fuji Transonic SL. First I bought a second stock seatpost so I wasn't cutting up the only seatpost that fits in my frame. I had a machine shop cut the top off, then cut a curve in the top to fit a cradle in and drill a hole through below for the cradle clamp rod. I took the cradle assembly from a round Hylix post I had. It would have worked perfectly if the machinist hadn't made a mistake then had to go shorter to fix his mistake, too short for the leg extension I like.

I thought about doing that but haven't been able to find a spare seatpost, and I don't want to risk destroying the stock one without a spare as that makes the frame useless.

That's why I didn't attempt it again. I couldn't get another post.

[Aeo]

Have a look here viewtopic.php?f=3&t=169798&p=1747407