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Old 06-10-09, 06:16 PM   #1
silver_ghost
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Pugsley IGH cable routing

Hey all,
I had a chance to build a Pugsley this morning, (they are a total blast to ride, by the way) and one little detail is bugging me. We put a Nexus 8 speed hub on the rear, which works great, but since the Pugsley's cable guides are brazed to the seat stays rather than the chain stays, the cable routing to the hub is a bit akward. I would like to angle the housing stop arm in line with the seat stay like in this picture here: http://thelazyrando.files.wordpress..../02/mike21.jpg but due to the orientation of the anti-rotation washers, I can't figure out how to do it.

Any help would be appreciated. tatfiend, I'm looking at you.

Thanks everyone.
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Old 06-10-09, 06:48 PM   #2
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Originally Posted by silver_ghost View Post
Hey all,
I had a chance to build a Pugsley this morning, (they are a total blast to ride, by the way) and one little detail is bugging me. We put a Nexus 8 speed hub on the rear, which works great, but since the Pugsley's cable guides are brazed to the seat stays rather than the chain stays, the cable routing to the hub is a bit akward. I would like to angle the housing stop arm in line with the seat stay like in this picture here: http://thelazyrando.files.wordpress..../02/mike21.jpg but due to the orientation of the anti-rotation washers, I can't figure out how to do it.

Any help would be appreciated. tatfiend, I'm looking at you.

Thanks everyone.
I did this once on a Giant Rainer frame. As long as the seat stay does not interfere with the casssette joint and the shift cable clears the chain where it crosses, it works fine. It's just a matter of finding which anti rotation washers position the axle where you need it to go.
Did you have any difficulty working out the chain line on the Pugsley? I've built up a number of Surly's but never a Pugsley. I'm just wondering because of the drivetrain offset to clear those gigundous tires.
Also, there is really no reason you can't run a continuous cable housing to the shifter and not worry about the cable guides. That's the way it's usually done on a gearhub install.
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Old 06-10-09, 07:29 PM   #3
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Originally Posted by silver_ghost View Post
Hey all,
I had a chance to build a Pugsley this morning, (they are a total blast to ride, by the way) and one little detail is bugging me. We put a Nexus 8 speed hub on the rear, which works great, but since the Pugsley's cable guides are brazed to the seat stays rather than the chain stays, the cable routing to the hub is a bit akward. I would like to angle the housing stop arm in line with the seat stay like in this picture here: http://thelazyrando.files.wordpress..../02/mike21.jpg but due to the orientation of the anti-rotation washers, I can't figure out how to do it.

Any help would be appreciated. tatfiend, I'm looking at you.

Thanks everyone.
Gee am I becoming that notorious?

I had an identical problem with building up my Steelwool Tweed frame with the Alfine hub. Due to differences in the keyed portion of the Shimano anti rotation washers only the ones designed for vertical dropouts will work with normal depth vertical dropouts so far as I can see. On the other anti rotation washers the key tab that fits in the dropout slot is further from the axle hole.

On the Steelwool I have a short section of shifter housing bent almost in the shape of an "S" from the bottom cable stop on the seatstay to the hub casette joint. Looks a bit odd but the shifting is fine with the Jtek bar end shifter I am using.

As the Pugsley uses horizontal dropouts, per the Surly web site, experiment with all of the Shimano anti rotation washers to see what set gives you the best angle for the casette joint. I would guess that the 7R & 7L (black and grey) AR washers will come closest to putting the casette joint arm near the angle that you want.
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Old 06-10-09, 07:49 PM   #4
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Gee am I becoming that notorious?

I had an identical problem with building up my Steelwool Tweed frame with the Alfine hub. Due to differences in the keyed portion of the Shimano anti rotation washers only the ones designed for vertical dropouts will work with normal depth vertical dropouts so far as I can see. On the other anti rotation washers the key tab that fits in the dropout slot is further from the axle hole..
I used the white/silver washer combo on the Giant, and had no issue with the washers. Never really remember noticing the difference in the hole to tab dimension, but I just looked it up and you are absolutly right about that.
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Old 06-11-09, 12:44 AM   #5
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Thanks for the help guys.

When I said "housing stop arm" I guess I really meant cassette joint. I knew there'd be a word for it, I just didn't know what it was. The housing does run continuously from shifter to hub, I just described it poorly.

So it's as simple as finding the right AR washer eh? I tried the only other one I found in the Nexus box, (if I recall correctly, it was yellow) it changed the angle a bit, but not quite enough. My cable routing is exactly the "S" shape you describe, tatfiend. It works fine, but looks a bit goofy (though I'm sure I'm the only one who will notice) and doesn't match the slick routing of the drum brake cable on the other side.

Chainline was no big deal, Dan. The customer ordered a Surly Mr. Whirly crank which is an external bearing crank with an extra long axle to accomidate the Pugsley's 100mm bottom bracket shell. The supplied literature reccomends putting one of the supplied spacers between the drive side bearing and BB shell when installing the crank on a Pugsley, but I found I had to lose the spacer to make things work with the Nexus.

How did you end up with a Steelwool down in Reno, tat? They are wonderful bikes, but I didn't know anyone outside of Canada had ever heard of them.
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Old 06-11-09, 12:32 PM   #6
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Thanks for the help guys.

How did you end up with a Steelwool down in Reno, tat? They are wonderful bikes, but I didn't know anyone outside of Canada had ever heard of them.
I saw it mentioned here and looked it up on the Canadian web site. Contacted them by phone and they offered me their last 2008 frame in my size at a sizeable discount. It had been built up as a show bike and had some minor paint dings as well as a slightly buggered rack mount thread on one dropout which cleaned up adequately.

Comfortable and IMO a good looking steel frame. The eccentric BB makes it nice for an IGH build though no provisions for down tube cable routing are provided. That is why I routed the shifter cable along the top tube and seat stays using the cable routing and stops that are provided for derailleur use. Cleaner appearing overall than fastening the cable via the down tube and using tie wraps for holding it I think.

Overall turned out to be a very good looking build with almost all parts in natural aluminum finish except for the Tubus IQ Fly rack that I put on it.
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Gear Hubs Owned: Rohloff disc brake, SRAM iM9 disc brake, SRAM P5 freewheel, Sachs Torpedo 3 speed freewheel, NuVinci CVT, Shimano Alfine SG S-501, Sturmey Archer S5-2 Alloy. Other: 83 Colnago Super Record, Univega Via De Oro

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Old 06-13-09, 07:00 PM   #7
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Originally Posted by tatfiend View Post
I saw it mentioned here and looked it up on the Canadian web site. Contacted them by phone and they offered me their last 2008 frame in my size at a sizeable discount. It had been built up as a show bike and had some minor paint dings as well as a slightly buggered rack mount thread on one dropout which cleaned up adequately.

Comfortable and IMO a good looking steel frame. The eccentric BB makes it nice for an IGH build though no provisions for down tube cable routing are provided. That is why I routed the shifter cable along the top tube and seat stays using the cable routing and stops that are provided for derailleur use. Cleaner appearing overall than fastening the cable via the down tube and using tie wraps for holding it I think.

Overall turned out to be a very good looking build with almost all parts in natural aluminum finish except for the Tubus IQ Fly rack that I put on it.
Still waiting to see some pictures of that Steelwool.
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