Pugsley Build Kit

Now that I have cut off the cantilever studs there is no going back.

I’ve ordered everything I need for the build now using a variety of sources including on-line vendors, my local bike shop, Craigslist and E-Bay.

I wanted to keep the cost under control so I chose a mix of Shimano XT and STX drive train components matched with a pretty unique shifting system that is well suited for the Pugsley. I’m using just the lever from a 9-speed Dura Ace bar-end installed on a Paul "Thumbie" mount that works just like an old school thumb shifter. Unlike Shimano’s complex rapid-fire shifters, which are prone to locking up or refusing to shift in cold weather, thumb shifters are quite reliable in sub-zero temperatures. In case a derailleur is damaged this setup also provides a friction mode that is missing on other Shimano shifters.

I chose the Speedway Cycles rim in a 70mm width. They cost the same as a Large Marge, are a bit wider and quite a bit lighter as the have a 1” hole between each spoke. I’m using a XT rear hub on one wheel and a Surly single speed hub rear hub on the other. Cuz’ Pugsleys don’t have front wheels.

For brakes I’m going to use Avid BB-7 disks with the smallest rotors – 160mm. I originally planned to get the massive 203mm downhill version because the price difference is only $20. But after riding one with smaller brakes the some snow recently and talking to the guy who owns it I think the there is plenty of power and what is really needed in the “limited-traction” environment is more feedback and better control so I got the smallest ones.

I using a Jones H-Bar for this – they seem to be the bar of choice for a Pugsley and work really well with the thumb shifter set up. I’ve got a 120mm Thomson stem and a set of XTR V-brake levers from another bike

I’m still thinking about the finish – I’ve got another few days before all the parts going to powercoat arrive so I have plenty of time. I’ve looked at a lot of white bikes, a lot of camouflage and really haven’t found what I am looking for.

I’ll be working with Spectrum Powercoating in Colorado Springs, CO. They have already done a white/como bike. I looked at it and found the pattern to be a little too organic. I envisioned something more geometric -- like the camo on WW2 ships. I found some of the current USA/USMC digital desert camouflage has a really cool pattern that might be able to translate to a white/silver palette well.

Also on Spectrum’s site is the “Other White Moots” which I really like. The nearly monochromatic effect of silver on white is exactly contrast I am looking for.

So I think I want a three color “digital” pattern using a white base, and light silver and medium silver pattern. The effect should be pretty subtle and only applied to the bottom third of the frame – the fork tips, BB cluster, chain-stays and rear drop-outs.