Another Beast Build

[blown240]

OK, so this is where I am at:

I have 50mm of trail with the fork in the position above if the dropout is centered with the back of the fork leg. Depending on where I mount the shock I have I can get up to 5 1/2 inches of travel, but that seems like too much. Im thinking 4" would be ideal for it. Also, with the height I would need for 5 1/2 inches of travel, my head tube angle would be 63 degrees. This isnt a DH bike so thats too slack!

Here are some other pics:

Im going to use the Fox Alps in the pic below. Im sure it will be the best of these 4 shocks.

 

[blown240]

WELL! My Fork is ALMOST done. I just need to make the dropouts and disc mount. Here is a video of the shock!

http://s268.photobucket.com/user/thebat ... 4.mp4.html

Its real smooth!

Its real heavy unfortunately, 9.4lbs. Most of the weight is in the legs. When I get some extra $$$ ill pick up a TIG and make them in Aluminum. I was shooting for 4" of travel and ended up with 4 and 5/16 so im really stoked!

Here are some more pics:

The business end:

 

[Bill in Houston]

i like it! i think it's too stiff, but i think you can adjust that. too cool!

 

[blown240]

Thanks Bill!

Ya, the stiffness is adjustable by the air pressure in the Fox damper. I an worried that the upper crown isnt going to be strong enough so i got a temporary fix for the issue. Last night I made strap that goes from the top to bottom crown and then wraps around the top of the crown. Im hoping that this design will at least warn me if the crown breaks before I smash my face into the ground.

I will for sure make new crowns, but I want to test the geometry first to see if there are any other big changes that need to be made.

 

[blown240]

I got my fork mounted and I took it for a VERY short test ride. I ended up having to trim a little bit of the crown to crown brace for steering clearance. It actually rides pretty good. The geometry feel alot like my Intense M1.

I still need to make the brake mount, cap the bottom of the fork legs, make a new upper crown, and decide how or if I'm going to paint it. I also may end up putting lighter oil in the shock to speed it up a bit.

Here are some pics:

 

[LukeTheJoker]

It looks really cool! Awesome work Blown240! 8)

Luke.

 

[ED-PV]

VERY nice build! Enjoyed watching it come together!

 

[kingfish254]

Nice work on that homemade fat Girvin fork!!!

 

[HRJG]

Awesome work on the fork. (How about a full shot of the car...?)

 

[blown240]

Awesome work on the fork. (How about a full shot of the car...?)

Here are a couple I took at Home Depot the other day. Not sure who's van it is, but I like it!

 

[HRJG]

Sweet car! And, I agree about the van, for sure.

 

[outskirtscustoms]

Nice van, I had a ratty one!

 

[Joosh]

Amazing work!

 

[blown240]

Thanks!

I got a piece of aluminum that I am going to make a new upper crown for. Its an inch thick, so it should be plenty strong!!

After that, the next step will be rear gears and a rear disc brake...

 

[blown240]

I got the new upper crown made last night. Its beefy! 1 inch thick and the shoulder bolts sink in a full 1/2 inch plus the threads. This fork is ready for some abuse!

 

[blown240]

I got my rear hub widened tonight.

I started with a regular Deore 9 speed casette hub with disc mount, 36 hole. I stripped it down to the shell and cut in half using a tubing cutter to get a straight cut.

Then I found this aluminum BMX axle peg. It came in a box of random stuff I got from my dad. I drilled a 1/2 inch hole thru it the long way and then, using a big bolt, I chucked it into my drill press:

I used a grinder with a flap disc to turn the peg down while it spun in the drill press:

I only shaved it down a little so that it would be a tight press fit into the hub halfs. It was TIGHT! I had to press it in with my vise.

A shot of paint and it looks great. If it ends up not being tight enough it can always be TIG welded, but I really doubt that will happen.

Next was the axle:

I used the axle from the hub and another from an extra hub I had. I tapped 1 end of each to accept a thread in screw. Once I got them threaded together, I welded them solid and ground down my weld.

I reassembled the hub and it came together perfectly!! Now I had a long bolt on axle with 190mm spacing. I just need to get some axle nuts that fit it.

http://i899.photobucket.com/albums/ac195/beastbike/BEAST/IMG_1661_zpsfee04287.jpg[/imh]

[img]http://i899.photobucket.com/albums/ac195/beastbike/BEAST/IMG_1662_zpsb624803a.jpg

For a casette, I got out an old project I made. Its a 11-42 8 Speed. Basicatly I made a 34t accept a chainring.

Next I need to get another 203mm rotor for the rear.

 

[LukeTheJoker]

Some cool stuff there! Love it! That monster cassette is awesome, will a normal derailleur move enough to work or will it require something special?

Luke.

 

[blown240]

Ya a normal derailer will work fine, you just need a frame with a long hanger. I had this cassette on my old Specialized and it was pretty good. So on the beast I will just make a long hanger, or mount it below the axle.

Here is a link to the 42t cog project:

http://forums.mtbr.com/drivetrain-shift ... 42237.html

 

[blown240]

Last night I got a few things done;

I widened my rear dropouts to 190mm and then bent them so that they were parallel again. Then I got an old derailer hanger from my Yeti and shaved it a bit to make a hanger for the Beast. I also mocked up the rear hub with the cassette and a derailer. And I drilled my rear rim.

I am going to have to run a chain guide in the front and some sort of tensioner in the rear. I may just go the old school route of an arm with a spring holding the derailer back.

HIgh gear is 22-11, which is about the same as the beast has stock. Low gear is 22-42, which should allow me to climb trees! :shock:

Here are some pics:

 

[outskirtscustoms]

Sweet setup! I'm watching and I can't wait to get my Beast!