Budget Hardtail XC Build USD$1000 - 100% COMPLETED
PS: I have posted this on Starbike Weenie Forum
After a hiatus of nearly 2 years, I have started a new project in October with following requirements/restrictions/specification:
1. USD$1000 on Bike Parts all inclusive. Would like to spend more but that's what I have
2. Built around a VERY specific frame (I LOVED this frame so much despite the obese weight)
3. Bike must be reliable and dependable to race 10 XC events in 2018. Mostly XCM type race and limited XCO
4. Bike is a Hill Climber XC variant with short travel and wide range gearing ratios
5. Built to suit my riding style and sizing
6. Must be 100% DIY - backyard project sort of stuffs
7. Buy cheap policy, NOS and good conditioned used components are preferred
It will be a sized 17" 26er XC Hardtail. Why 26er? well I am 164cm tall and with a steady weight of 57-58kg - rather on the smallish side. Yes I have raced a 29er before in 2015 and 2016 but ultimately to ride a 29er, I was forced to use a sized 15.5" frame which I found to be a bit finicky to my bones. I did switch to a 650b somewhere in between but still it was a sized 15.5" frame. Late 2015 I switched to a sized 16.5 26er and have been getting better results in XC races - with less punishing after effects post race. So I made up my mind that I will stick to 26er 16.5-17".
Let's start into the juicy parts then.
Stage 1: The Frame
I have been eyeballing this frame for quite a while. It was a NOS BMC TeamElite 05 Aluminum 6061 Sized 17". The perfect size and geometry that I have been craving for. I have had great experience before with Giant XTC 26er 16.5" and I was confident that this BMC would be better suited for my use. And the price was definitely spot on.
Price: USD$ 123.00
![Image]()
However, there's one BIG problem. It has the weight of an elephant!:eekster:
![Image]()
1883g for naked frame is outright obscene for any weight weenies. Apparently BMC decided to go for Apocalyptic durability for this frame with much thicker gauge than you would normally see on Taiwanese brands. Probably can support a rider up to 200kg without even creaking...LOL
And so begin the extensive diet program - with the dark arts of Drillium, Hack, Grind and Shave of the good old 80s come into practice. The time when racers drilled and hacked their metal bikes to death....carbon fiber was probably exclusive only to NASA Space programs back then
Paint Strip:
![Image]()
Yep, it's 65g of solid paint scraped off, and that's not all of them. Some were swept away earlier
![Image]()
And so I ended up still at 1.8kg after paint stripping - that's still 69g shaved by just removing the paint
![Image]()
Many many hours later after extensive Drillium, hack, grind and shave - with removal of cantilever bosses, cable brake bosses, shortened headtube, shortened seat tube ends, drilled headtube, drilled BB housing, removed hydro hose bosses, grinded edges etc.......the bare Frame now weighs 1650g
Yep I know, it is insanity to drill holes on frames......but I am doing this with full acknowledgement of the risks and implications. Bike builders of old has been drilling gaping holes on BB housing and headubes - I am just applying the idea to practice
Next, finishing the frame with a pretty coat.
![Image]()
Complete with decals and coat - Yamaha Star Grey color code
And I am penalized with 16g of weight added in the final product. A weight penalty I am willing to absorb for a bit of eye-candy
![Image]()
In the end, I managed to reduce 217gm from the original weight - not too shabby eh? XD
Stage 2: Front Suspension
Due to limited budget, I decided to use SR SunTour EPICON X1 100mm. I have had very good experiences with 26er EPICONs before so this was a no brainer.
Price: USD$ 147.00 NOS Gen 1
![Image]()
Weight: 1610g (1593g after steerer cut)
Lower housing modification & hack
![Image]()
![Image]()
40g shaved off the lower housing with removal of excess ridges which was meant to support heavier riders. Now this fork can only support 65kg max riders
![Image]()
![Image]()
And so the initial weight after re-assembly was 1475g. Final weight is 1463g after further tune-ups. Oh yes, plain RED because I love the contrast vs the gunmetal frame color
In total, 147g was removed from the forks. Now operating 80mm travel and without rebound dampening springs which I can live without
Stage 3: Drivetrain
I have decided on running 1X11 Mega Wide Range for this XC Climber.
The Crankset:
The cheapest option for a Shimano Hollowtech Crankset was an Alivio M4000 Triple. Totalled at USD$85 (Crankset + 32t Oval Chainring + Aluminum Chainring Bolts + Ti Bolts)
![Image]()
Shimano Alivio stuffs are made to be used through zombie holocaust so it is impossible to break this thing. The weight at 1004g matches the sturdy built
![Image]()
Initial attempt at conversion to 32t single ended up at 615g - NOT good enuff...
![Image]()
![Image]()
That's more like it!. Crank Arm length was reduced to 165mm from 175mm - this primarily because I am more of a Spinner than Cruncher - spinning higher cadence with shorter cranks is less painful to my Hip Flexor. And shorter cranks are lighter too. The spider was totally reworked and substantial chunks of aluminum were shaved from the assembly. The Chainring gets traditional Drillium treatment too
![Image]()
For a $85 crankset to weigh a mere 487g makes me a happy man indeed thats 517g gone from the original assembly!
The Cassette:
I jumped into the Mega Wide Range bandwagon and the cheapest 11-50t available in the market was a Bolany 11-50t 11 Speed priced at USD$42
![Image]()
WHAAAT!!!! 660g! :eekster: this thing weighs as much as someone's full bike here...LOL!
And so I spent over 40 man hours on getting rid of the overtly excessive weights...with extreme Drillium, Grinding and MORE grinding hahaha
![Image]()
![Image]()
First the Mega Cluster gets extreme makeover which resulted in 157gm removed
![Image]()
![Image]()
![Image]()
![Image]()
Finally...
![Image]()
395g isn't exactly a Weight Weenie standard, but for $42 cassette with a weight reduction of 265g overall...I would not complain
The rest of the Drivetrain:
Rear Derailleur - Shimano Ultegra RD-6800 SS Short Cage! got a bargain deal at USD$49.00 for an almost new RD sold by a Roadie fresh from his new bike. I have always suspected that a short cage RD would perform better on 1X system due to the stronger Cage springs and shorter chains, for as long the reach problem is solved for giant cogs (of which the RD Extender addresses) - now is the time to test my theories...
![Image]()
![Image]()
And so the RD was originally 197g and I decided not to go ape **** on modding this unit. Just grinding works on the cage and replacement of Pulleys to Meroca Aluminum. End results is 182g. (Once I have the funds I will go for DuraAce version)
The Rest -
![Image]()
![Image]()
![Image]()
![Image]()
The remaining drivetrain parts are:
- Shimano tuned length shifter cables (Free - already owned)
- RD Extender ($7.30 New)
- Shimano Alivio M4000 BB51 (Free - already owned)
- KMC X11EL 116 Chains tuned length ($35 New)
- Shimano Ultegra SL-RS700 1X11 Shifter ($74) Purchased practically new from an owner of folding bike. This shifter actually uses the same shifter chassis for XTR M9000 11spd. So at this price it was quite a bargain
Assembled Groupset!: Mocked up dry run with my spare training wheels
![Image]()
![Image]()
Hahaha, so a short cage RD does work on giant cogs. In fact the shifting performance was crisp and smooth. Even at 50t, the RD actually still have a bit of play to stretch flatter. And this means I don't really need a clutch RD because the SS cage tension was adequate to prevent chain slap.
PS: I have posted this on Starbike Weenie Forum
After a hiatus of nearly 2 years, I have started a new project in October with following requirements/restrictions/specification:
1. USD$1000 on Bike Parts all inclusive. Would like to spend more but that's what I have
2. Built around a VERY specific frame (I LOVED this frame so much despite the obese weight)
3. Bike must be reliable and dependable to race 10 XC events in 2018. Mostly XCM type race and limited XCO
4. Bike is a Hill Climber XC variant with short travel and wide range gearing ratios
5. Built to suit my riding style and sizing
6. Must be 100% DIY - backyard project sort of stuffs
7. Buy cheap policy, NOS and good conditioned used components are preferred
It will be a sized 17" 26er XC Hardtail. Why 26er? well I am 164cm tall and with a steady weight of 57-58kg - rather on the smallish side. Yes I have raced a 29er before in 2015 and 2016 but ultimately to ride a 29er, I was forced to use a sized 15.5" frame which I found to be a bit finicky to my bones. I did switch to a 650b somewhere in between but still it was a sized 15.5" frame. Late 2015 I switched to a sized 16.5 26er and have been getting better results in XC races - with less punishing after effects post race. So I made up my mind that I will stick to 26er 16.5-17".
Let's start into the juicy parts then.
Stage 1: The Frame
I have been eyeballing this frame for quite a while. It was a NOS BMC TeamElite 05 Aluminum 6061 Sized 17". The perfect size and geometry that I have been craving for. I have had great experience before with Giant XTC 26er 16.5" and I was confident that this BMC would be better suited for my use. And the price was definitely spot on.
Price: USD$ 123.00
However, there's one BIG problem. It has the weight of an elephant!:eekster:
1883g for naked frame is outright obscene for any weight weenies. Apparently BMC decided to go for Apocalyptic durability for this frame with much thicker gauge than you would normally see on Taiwanese brands. Probably can support a rider up to 200kg without even creaking...LOL
And so begin the extensive diet program - with the dark arts of Drillium, Hack, Grind and Shave of the good old 80s come into practice. The time when racers drilled and hacked their metal bikes to death....carbon fiber was probably exclusive only to NASA Space programs back then
Paint Strip:
Yep, it's 65g of solid paint scraped off, and that's not all of them. Some were swept away earlier
And so I ended up still at 1.8kg after paint stripping - that's still 69g shaved by just removing the paint
Many many hours later after extensive Drillium, hack, grind and shave - with removal of cantilever bosses, cable brake bosses, shortened headtube, shortened seat tube ends, drilled headtube, drilled BB housing, removed hydro hose bosses, grinded edges etc.......the bare Frame now weighs 1650g
Yep I know, it is insanity to drill holes on frames......but I am doing this with full acknowledgement of the risks and implications. Bike builders of old has been drilling gaping holes on BB housing and headubes - I am just applying the idea to practice
Next, finishing the frame with a pretty coat.
Complete with decals and coat - Yamaha Star Grey color code
And I am penalized with 16g of weight added in the final product. A weight penalty I am willing to absorb for a bit of eye-candy
In the end, I managed to reduce 217gm from the original weight - not too shabby eh? XD
Stage 2: Front Suspension
Due to limited budget, I decided to use SR SunTour EPICON X1 100mm. I have had very good experiences with 26er EPICONs before so this was a no brainer.
Price: USD$ 147.00 NOS Gen 1
Weight: 1610g (1593g after steerer cut)
Lower housing modification & hack
40g shaved off the lower housing with removal of excess ridges which was meant to support heavier riders. Now this fork can only support 65kg max riders
And so the initial weight after re-assembly was 1475g. Final weight is 1463g after further tune-ups. Oh yes, plain RED because I love the contrast vs the gunmetal frame color
In total, 147g was removed from the forks. Now operating 80mm travel and without rebound dampening springs which I can live without
Stage 3: Drivetrain
I have decided on running 1X11 Mega Wide Range for this XC Climber.
The Crankset:
The cheapest option for a Shimano Hollowtech Crankset was an Alivio M4000 Triple. Totalled at USD$85 (Crankset + 32t Oval Chainring + Aluminum Chainring Bolts + Ti Bolts)
Shimano Alivio stuffs are made to be used through zombie holocaust so it is impossible to break this thing
. The weight at 1004g matches the sturdy built
Initial attempt at conversion to 32t single ended up at 615g - NOT good enuff...
That's more like it!. Crank Arm length was reduced to 165mm from 175mm - this primarily because I am more of a Spinner than Cruncher - spinning higher cadence with shorter cranks is less painful to my Hip Flexor. And shorter cranks are lighter too. The spider was totally reworked and substantial chunks of aluminum were shaved from the assembly. The Chainring gets traditional Drillium treatment too
For a $85 crankset to weigh a mere 487g makes me a happy man indeed
thats 517g gone from the original assembly!The Cassette:
I jumped into the Mega Wide Range bandwagon and the cheapest 11-50t available in the market was a Bolany 11-50t 11 Speed priced at USD$42
WHAAAT!!!! 660g! :eekster: this thing weighs as much as someone's full bike here...LOL!
And so I spent over 40 man hours on getting rid of the overtly excessive weights...with extreme Drillium, Grinding and MORE grinding hahaha
First the Mega Cluster gets extreme makeover which resulted in 157gm removed
Finally...
395g isn't exactly a Weight Weenie standard, but for $42 cassette with a weight reduction of 265g overall...I would not complain
The rest of the Drivetrain:
Rear Derailleur - Shimano Ultegra RD-6800 SS Short Cage! got a bargain deal at USD$49.00 for an almost new RD sold by a Roadie fresh from his new bike. I have always suspected that a short cage RD would perform better on 1X system due to the stronger Cage springs and shorter chains, for as long the reach problem is solved for giant cogs (of which the RD Extender addresses) - now is the time to test my theories...
And so the RD was originally 197g and I decided not to go ape **** on modding this unit. Just grinding works on the cage and replacement of Pulleys to Meroca Aluminum. End results is 182g. (Once I have the funds I will go for DuraAce version)
The Rest -
The remaining drivetrain parts are:
- Shimano tuned length shifter cables (Free - already owned)
- RD Extender ($7.30 New)
- Shimano Alivio M4000 BB51 (Free - already owned)
- KMC X11EL 116 Chains tuned length ($35 New)
- Shimano Ultegra SL-RS700 1X11 Shifter ($74) Purchased practically new from an owner of folding bike. This shifter actually uses the same shifter chassis for XTR M9000 11spd. So at this price it was quite a bargain
Assembled Groupset!: Mocked up dry run with my spare training wheels
Hahaha, so a short cage RD does work on giant cogs. In fact the shifting performance was crisp and smooth. Even at 50t, the RD actually still have a bit of play to stretch flatter. And this means I don't really need a clutch RD because the SS cage tension was adequate to prevent chain slap.
