Carbon Bike Frame Project: Part 4 | Making the Replica!!

Picture taken by my supplier for me to review the paint job

After much delay and corresponding with China Supplier, finally i decide to go ahead with ordering the frame. I managed to get a Cannondale Supersix fork from eBay. The fork is white and red, therefore decided to make a replica with it.

Frame with Cannondale Super Six

Cant wait to just put both the fork and frame together. Fork from USA while frame from China. Irony.. They fit each other well! Was abit disappointed with the paint job. They only coat it with one layer, a slight knock on it will chip/scrap the paint away.

Frame with custom reflective decals

How can it be a replica without decals.. Ask my friend whom is specialized in making decals, MZ Decals. Very pleased with his workmanship and fast delivery. I was expecting 1 week, yet he told me it will be done in 1 day. But i decided not to rush the job and in the end waited for only 2 days! Reflective decals, hopefully now cars will not have excuses to say they cant see me!

Finally frame is almost done. Left the cutting of seat tube and steerer tube. Will be looking for the groupset, wheels and contact points.


Adrenalin Pumping
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Carbon Bike Frame Project: Part 3.5 | Inspiring Bike Brand

This post is nothing to do with the progression of my carbon bike project. Just to share this blog, which records the process of them sourcing, designing and testing the own brand.

http://velocitebikes.blogspot.com

Designed bike frames for road made of all 3 common materials, aluminum, titanium and carbon. Namely their Selene, Millennium, Helios, Magnus and MTB frame, Flux.

Selection of wheels tubular and clincher version, aluminum and carbon rim of different width. Many more.. Slowly go through their posts, especially from first post.

Had been sourcing my carbon frame from China, Hong Kong and Taiwan. Hence somehow see the similarity of their products and the OEM frames. No much different. But from their post, i learn what to look out for and how to test my OEM suppliers.

Asking technical question (which answer might not make sense to you) is a good way to filter out the supplier, asking for quality pictures etc.. Fortunately the supplier which i have been corresponding is able to provide me these information without much hesitation, without throwing the questions back to me.

From these at least you can tell they know their products. Even if they don't, and the information are faked to me, at least they are prepared for such questions. Some pictures sent to me by the suppliers

BB, Head Tube and Dropout Stress Test

Matte Finish

Currently what the supplier is able to offer me is the above frame ( mine is ISP). Seems like the exact copy of the Trek Madone. However i don't really like the fork design, not fierce enough! Sourcing out other suppliers and monthly email the supplier if there is any new fork design.

From the picture and frame drawing, the rear seat stay is only 1 cm thick! Damn scary to ride on it. But consider Cervelo having the same thickness and my bike-look ego doesn't allow me to lose out on it. haha!

Stay Tuned For More Updates
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Carbon Bike Frame Project: Part 3 | Copy Which Frame Maker

Can see that my quest for a new frame is advancing. Whether or not i bought one in the end would not be that important now. This part will narrate on my search for the ideal supplier/manufacturer, new things that i tried to do which gave me much experience in dealing with oversea parties. If you had yet to read Part 1 and Part 2, you can read them first.

Have been doing much research on bicycle frame manufacturers, especially from Mainland China, Hong Kong and Taiwan. Found many interesting designs and had my heart stuck on one of them already.

Why i choose this design.
Personally i like to copy the theme of some renowned frame makers, had my first project on CUBE's HPT. But turned out to be ugly due to the custom geometry! I liked the skinny 1cm thick seat stay which is much similar to what Cervelo is having. But i soon found out that not just Cervelo have this feature, few other frame makers also have it!

See the similarity!! Main difference is the Geometry and Fork used. Also means more design to refer on.
Cervelo: 3T
Cannondale: Own house brand
Cube: Easton EC90 SLX
Trek: Own House Brand

Set my mind to 'copy' the look of CUBE, even up to their EC90 SLX fork, Syntace handlebar and stem as Cervelo fork is too expensive. Just when i can start champagne popping, all the cheering and stuff. Brain starts cranking on how to get the red design on the plain black carbon frame. I then noticed the weird head tube on the China Made Frame, using tapered head tube!! Damn It! Since when they started moving so fast with the trend in Cycling Industry!

In fact not many frame makers have moved on with the tapered head tube design. A pretty recent change in the industry which had a few critics over the benefits of having it. Can google it if you want to know more. Basically its more of stability and steering/handling issues, maybe some strength contribution. I haven't gone much into it.

With a tapered head tube, the immediate problem i face is i cant use the EC90 SLX fork! Had thought of getting/fabricate a adapter to fit the 1 1/8 fork to the 1.5" head tube. But find that it will look weird and more hassle getting the adapter. CUBE design with the fork is thrown into the rubbish bin, same for Cervelo.

Left with Trek Madone and Cannondale. Luckily they are both using tapered head tube. Trek is using the same fork as what is available by the China Supplier. But few friends find the design sucky. I have the same impression too. Hence design in mind, left only Cannondale.

Problem with Cannondale is, its hard to get their fork as they often comes as a package with their frame! Tried eBay, so far had came across 2 forks, but price exceeding 130USD..

Carbon Bike Frame Project: Part 2 | Change of mind, Material of Frame

For those who came to this page first. It will be good to read up on Part 1 before carrying on.
Part 1 had left me hanging for another couple of weeks before i stubble randomly into some Chinese Carbon Frame Manufacturing Site. Saw this frame, which made me pause for a moment. Rethink the material, possibility of using carbon as my choice of material.


Noticed the nice Matt carbon finish? Unlike the usual 3k and 12k finishing. They are able to product Matt finishing, which they claimed as UD (unidirectional). Similar finishing as BMC SLC (one of my dream frame). But of course, not the same technology used, nano-carbon. But seriously who cares, if its cheap! haha~

Received some critics on the weaving of frame which claimed to have effect on structural strength. From my knowledge (back then), I understand that the weaving only affect the external look. However, few says the weaving pattern, 3k and 12k, 3k produce stronger and stiffer frames. However after seeing the above picture, i sets me wondering whether weaving really does play a role in frame strength?

Hence i decided to make use of my off day to do a research on carbon frame structure and weaving pattern. All you need to do is just open a new tab and type in the URL, www.google.com

I have arranged the sites and forums in order to have a better flow of idea on carbon weaving properties. Basically, the sites are branched out from the forum.

1. Bike Forum
2. Stork Bicycle
3. Weightweenie Forum
4. Calfee Design
5. Toray Carbon Fiber
6. Properties of Carbon Fiber

*Easier to start off reading Stork Bicycle and Calfee Design as they are meant for consumers.

My conclusion is, Strength of frame cant be judged by the weaving pattern, they only provide cosmetic look and riding feel. Instead we should be looking at the grade of the carbon fiber used e.g. T700, (read Toray Carbon Fiber) and the Tensile Modulus (measured in MSI, read Calfee Design and Properties of Carbon Fiber)

12k is not as weak as we think. They are cheap and slightly heavier. Console myself for having it. haha!

Carbon Bike Frame Project: Part 1 | In search of the right design

For those who knows that now I'm keen in getting a ISP (integrated seat post) frame either carbon or titanium. Initially only did research (here & here) on the clamp-on seat post system adopted by different renowned bicycle frame makers such as Look, Scott, Giant.

Set my eyes on the Ritchey Stubby Clamp-on Seat post, as it CLAMPS ON the 31.6mm dia seat tube instead of Look which is INSERTED INTO. Didn't bother with Giant as its clamp is unique for their frame alone.


However, read much reviews stating that this piece of clamp is 100+g which does not provide much weight saving (from weight weenie). Considering that the frame already has a extra long seat tube (acting as seat post). Its weight does not justify the use of this ISP system. Well then some German guy managed to forge a clamp which offer much weight saving.

After seeing this design, i crack my head for few weeks on how to get it fabricated in Singapore (rebound centre) or Ordering it in. Both options are pretty expensive!!

Some pictures of ISP built bike to continue inspire me to seek out for the prefect ISP frame.

Titanium ISP frames just looks so gorgeous!! Imagine it being built up with white, silver and titanium colour.

Pondering about the ISP system again for a few weeks, came across this clamp while surfing pedal force website and saw this seat post clamp


Made of carbon/aluminium. Seems like a cheaper alternative compare to the 2, i considered before. BUT, pedal force is not selling this piece separately.. Disappointed, my lead somehow hit another wall.

Bike Fitting using Motion Analysis

Just did some DIY bike fitting at home over the weekend, after viewing almost all the bike fitting clips in YouTube. Saw one of the clips in YouTube, stating how they used motion analysis to do bike fitting/analysis. Just nice, Grace who has trainer, is going to Port Dickson over the weekend for race. So borrowed the trainer, hook up my camera and ACTION!

Riding on a new bike again, confused with the bike fitting theories recommended by different people. So decided to film myself to see how i look like while riding instead of hearing people's comments. Perspective can be different from view's of different people, which leads to the wrong buy of my titanium frame.

Currently judging by personal comfort, going for longer rides to see which area needs to improve. But worried that my current 'comfort' position might be straining my knees, or not optimizing my effort when riding.

Google online, looking for 'ideal' leg bend angles, poseur etc... Trying to find the commonly used figures.

Upper body Poseur

Looks pretty decent to me, not to upright nor to forward.. Looks like I'm tipping toes when pedal is at 6 o'clock (had lowered seat by 5mm)

Leg Bend Angle

As said earlier, googled on leg angle. Mostly recommend 30-35 deg. I don't know how they get that figure. What i assumed is the difference in angle when knee is bent from a straight poseur.
The above picture is not very accurate, forget to paste a sticker over my pelvis bone. So have to estimate the point.

Knee Over Pedal

This is to check the fore/aft of the saddle. Looks fine to me. Except on a few occasions, my knees will move forwards by 1-2cm. On a clip showing bike fit for tri bikes, they figured this guy with 3-4cm knee in front of the pedal spindle. So i think its fine, anyway i don't always move forward.

Overall was glad that i can see how i ride and some figures regarding my current position. Problem with using motion analysis is the camera angle and position of it from the user. The areas away from the camera focus point tend to convex out. Still cant beat bike fitting with the help of a friend doing the measuring while you cycle.

Sorry, didnt wanna go throught the features of the software im using. Pretty tired of drafting this post already. The only main features is, it can slowdown and pause split-seconds of your action and take measurements.


Bike Fit Anatomy
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Carbon OEM Bike | New Step to Bike Building

8 June: Auction for frame, fork and seat clamp ended
10 June: Payment made, via paypal. Alot cheaper than whats stated in eBay
15 June: Frame, fork and seat clamp arrived!!! - Seat Clamp does not goes well with the frame...
15 June: Most of the groupset installed on the bike except front de, front brake caliper
15 June: Bought a Ritchey WCS headset from eBay
16 June: Ritchey WCS headset shipped, need to wait 3-5 days
16 June: Changed and fixed the Mavic Ksyrium SL wheels on bike
17 June: Still waiting for headset
-Need-To-Do list

1. Buy shim,
2. Spray front de clamp black,
3. Cut fork steerer and cable housing

22 June: Headset finally arrived!
24 June: Decided to send the bike to be setup.
Damn, the whole setup cost me $66!! F$%^ expensive... Will ask them for the breakdown.

-Total tasks done:

1. Cut Steerer Tube
2. Install Fork Race
3. Install Chain
4. Install Cables and Housing
5. Tuning
6. Wrap Bar Tape

I don't think it worth $50!!!

Bike Fitting 101: Part 2

Ok! after getting the bike for more than 1 month, ride with group for over 90km, climbed a few hills. These are my few observation.

Lower Back ache, which i don't have when using my old ride. Was quite disappointed. Funny thing is, only for short hard rides which i really push. Hills don't have, long distances (90km) abit. Find it quite cramp when i go to drop position (not very sure, need to verify).

Incomplete service. Find that i should go for the Powerfoot Cleat Alignment to fully undergo the full standard package from Bike Butler. Even if the benefits doesn't surface much, completing the standard package kinda earn me the right to give comments and review on the service.

Expose to more bike fitting tools. Saw them online and in Butler's place but wasn't included in the part 1 package. Seeing is believing, applying is experiencing. Had did some search online and Youtubed for bike fitting services in U.S site. So much science involved, often think that such services are only for pros. www.smartcycles.com, www.bikefitkit.com

Ok now go into the Powerfoot Cleat Alignment Package

Fore foot measurement. Picture tells a million words, so i think video can save me more time. Youtube, Bike Fit Cleat Wedge

Conclusion: Left leg shorter.. Again sound like some handicap guy.. -_-". Shown to me that the rail of my saddle is tilted to 1 side. Not very obvious but can be seen.

Action: Added 5mm of wedge on the left shoe and 10 deg wedge on both shoes. And some adjustment to the cleat position. Ever adjustment is done after a few mins of ride with the heaviest gear ratio.

This is not my pedal

Vertical Stroke Adjustment. Visualize a line cutting across the dot on the knee and shoe. We should be pedaling with the dot on knee in line with the dot on shoe.

This is also not me.

Personally i find that this got to do with the riders riding proficiency. I have problem coordinating my left leg, as i focus too much pedaling by my right. So i have to constantly remind myself to coordinate with my left leg. Need to do more single leg drill.

Rotational Adjustment of Cleat. With the use of RAD aka chopstick

This is not my shoe

RAD is a dummy jig for clipless pedal, however with more float exist. White Stick attached to the cleat while Red Stick to the Pedal. So when pedal, we can see clearly how much ankle movement is there during pedaling.

Pedaling Technique Correction
This is done concurrent with cleat alignment and vertical stroke alignment.

Ok all set! Finalised by marking the position of cleats with marker. Now is to keep riding and feel for discomfort. For more review of this package.

Review / Comments
Only rode for short distances. However now paying more emphasis on my left leg. Need to play more attention to body discomfort even for the slightest. E.g. Numbness on hand and toe, which leg first? Lower lumbar ache, which side. Any pain on knees, etc..

For anyone keen in this service, ask yourself the above mention questions before you visit Bike Butler. Also these following 2 questions

If pricing is an issue, ask yourself whether the current bike position is affecting you or bring you any discomfort. If not then stick with your old ride.
If 'looking garang' on a bike is important, ask yourself whether you are willing to change to a more upright position with handlebar brought more closely to you.

Rider should go for Bike fit follow by the Powerfoot cleat alignment. Get a fitting bike before going into pedaling efficiency.

Some websites for reference:
http://www.thebikebutler.com/
http://www.bikefit.com/
http://bikefitkit.com/
http://www.smartcycles.com/

Video Clip of bike fitting in US.
Clip 1
Clip 2

Bike Fitting 101: Part 1

Finally finish all the bike fitting services provided by the Bike Butler. Quite an experience and educational. It allow me to pay more emphasis on my bike riding.

Why i go for it?
2 year ago, before i entered Army, was recommend to visit Bike Butler for Bike Fitting Service. Price then to me is pretty steep (even now). 100+ for Bike Fit and Positioning and another 100+ for Powerfoot Cleat Alignment. Hence, didn't go for it as I'm fine with my old bike position.

2 years later, with more positive reviews from Coach and illusion of me being more wealthy with the army allowance. I went for the bike fitting. Was so decided to get a new bike that i sold off my old ride and hoping to get one from the Bike Butler.

Bike Fit Positioning
First thing Butler did was throw me on his 'Measuring Station'. Figures shows that i had short arm short leg. -_-" sound like turtle...

Next I'm introduced to this 'AFS Bike Tool' a dummy bike jig used to assess my riding posture and my custom frame measurement.

After some body alignment... Wala! My new custom made titanium frame!

Some measurement of the frame:
Top Tube: 51cm (actual), 53cm (virtual)
Seat Tube: 44cm (CTC), 48cm (CTT)
Seat Tube Angle: 72 deg
Head Tube: 16cm
A pretty sit-back and up-right position with the 72 deg seat tube angle and long head tube.

Bike is then setup with the parts which i like, also tried to copy the theme of CUBE HPT but didn't turn out well.. Making of the CUBE

After service review & thoughts
Bike Butler have this signature mark on most of his bike. Yes~ the super long Head Tube which had invited many comments about it. Should really see my Coach ride... With the more upright position, i constantly remind myself to apply lesser pressure on my palm and work my core harder to maintain the nice curve of my back.

Leveling the handlebar and saddle height, makes the rider looks less 'garang'. But allowing the rider to sit in the 'neutral/optimal' position. Personally I'm still trying to find out more on this 'neutral/optimal' position specially on how arch should our lower back be? Tried googling it but not much findings.

Compared the Bike Butler's fitting with the US Fitting Service. Of course with more resources and support, US looks much better. They can provide video clips of you riding before and after the service. Can try go 'YouTube, Bike Fitting' as Bike shops actually uses YouTube as a media to market their bike fitting service.

Lastly Bike Fitting Service is like consulting a doctor. They can diagnose through a few tests to tell where is the problem. But without proper input from the patients, they still cant make proper judgement and prescription. E.g. Pain.. How pain? Discomfort, How discomfort is discomfort? Same for ache, sore, numb.. Especially for beginners.. isn't pressure on hand and buttock common? Will a series of tests and questionnaire help?

Bike Project: The Judge

Yes now preparing to send the bike to be setup. Praying hard that it will be done by next wed. Also hope that the colour scheme will be nice and have an equal spread of white and black.

Initially had some ideas of respraying the frame and fork, giving them a brand new set of decals, changing the fork to a Manitou Black Elite air fork to add on the street look.

BUT, pocket was already torched to a big hole which requires patching up for the next few months. Well GST offset package really came in at the right time.