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  1. #1
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    can I swap a single cog in an Ultegra cassette?

    Hi. My Ultegra cassette is 11-12-13-14-15-17-19-21-24-28. I don't really need the 11, and the jump from 15 - 17 is a too much. Can I remove the 11 and replace it with a 16? If so does Shimano sell individual rear cogs? does anyone sell individual rear cogs? Thanks

  2. #2
    Real Men Ride Ordinaries fuzz2050's Avatar
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    In an Ultegra cassette, chances are at least some of the cogs are bolted together, or they may even be permanently joined to a spider. Without seeing your individual cassette, it's hard to say if you can do this or not.

    It is however, generally speaking, possible to build custom cassettes. I think Miche sells individual cogs, or you can always pull them from worn out cassettes.

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    No can do. The 12t on your cassette cannot be used as the end cog, just buy a cassette with a 16.

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    The closest Shimano cassette to what you want is a 12x27 10-speed. It's geared 12,13,14,15,16,17,19,21,24,27. It is definitely my favorite as I'm in love with a 16T cog also.

    I once made a 13x27 9-speed from a 12x27 9-speed by removing the 12 and 13, substituting a first position 13T cog and a single 16T with it's spacer. It worked wonderfully but 16T individual cogs are no longer anywhere to be found.

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    It would be possible if you could find the needed parts, a first position 12 with built-in spacer and a single 16. Your best bet would be to find someone with a good salvageable cassette with the needed parts, or possibly an NOS cassette on e-bay with the needed parts. If you find what you need be sure that the parts are 10-speed Shimano compatible.

  6. #6
    Constant tinkerer FastJake's Avatar
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    Quote Originally Posted by fuzz2050 View Post
    chances are at least some of the cogs are bolted together, or they may even be permanently joined to a spider.
    All the cassettes I've worked with have either been bolted together or riveted. The bolts/rivets are not essential. They can be (generally) easily removed.

    I make custom cassettes when I'm not happy with my current one. Your best bet is to find a donor cassette and steal its sprockets. You could run an 11-13-14-15-16-17-19-21-24-28 if you find a 16.

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    Quote Originally Posted by FastJake View Post
    .....if you find a 16.
    That's the hard part!

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    Older cassettes usually have loose cogs (all of them). I have DA7400 8speed ad all of the cogs are loose (with individual spacers, only the last splined cog has an integrated spacer, the last one closes the cassete withe threads - Uniglide), it has the 16T in it (13-14-16-18-20-22-24-26) - 13 is a bit high but compensates with 53T chainring.

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    Wilma!! Randallissimo's Avatar
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    I just installed an Ultegra 12- 27 today and I can tell you I love it. Don't mess around, get the right cassette and be happy.

  10. #10
    Gear Combo Guru Chris_W's Avatar
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    Once you start customizing your cassette, you might never stop. I've been fiddling for a while, and just got my hands on the cogs that I needed to finally make a 12-28 cassette with the exact combination that I wanted. In the end, I needed 3 separate 10-speed cassettes:

    A "junior" Ultegra 16-27 (cheap eBay purchase) - I sawed through the pins/rivets connecting the individual cogs and took the 18 and 20 tooth cogs (these sizes are particularly hard to find as individual cogs).
    A SRAM 11-28 (I bought this cassette thinking that it would be good for me, but I couldn't handle the 19-22 jump and the 15-17 jump also wasn't great) - I took the 22-25-28 cogs that were mounted on a lightweight aluminum spider.
    A Dura Ace 12-25 (stock cassette on a bike I bought) - I took the 12, 13, 14, 15, 16 tooth cogs.

    The resulting cassette has: 12,13,14,15,16,18,20,22,25,28.

    This is an awesome setup that gives the best compromise between gear range and jumps between gears. It shifts fine, although not quite as well as a stock cassette would in the two positions where it switches between cassettes (16-18 and 20-22) - I assume this is because the shifting ramps and gates are not lined up. Some of the leftover cogs have gone into other custom cassettes on my and my wife's bikes, I'm sure that I'll use others in the future also.

    I don't know why no-one is selling such a 12-28 cassette. IRD and BBB make 12-28 cassettes, which I've previously used, but they are both 12,13,14,15,17,19,21,23,25,28, so both have the annoying 15-17 tooth jump. I've traded this for the 16-18 jump, which is almost the same but is not in quite such a critical point in my speed progression (yes, I obsess about my cadence WAY too much).
    Last edited by Chris_W; 10-04-10 at 10:44 AM.

  11. #11
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    Quote Originally Posted by Chris_W View Post
    I don't know why no-one is selling such a 12-28 cassette. IRD and BBB make 12-28 cassettes, which I've previously used, but they are both 12,13,14,15,17,19,21,23,25,28, so both have the annoying 15-17 tooth jump. I've traded this for the 16-18 jump, which is almost the same but is not in quite such a critical point in my speed progression (yes, I obsess about my cadence WAY too much).
    As I mentioned above Shimano sells 12x27 10-speed cassettes that do include the very useful 16T cog. I think I'd find the 16 - 18 jump in your cassette just as bothersome and the Shimano is a straight block from 12 to 17. The 17-19 gap is no problem for me.

  12. #12
    Gear Combo Guru Chris_W's Avatar
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    Quote Originally Posted by HillRider View Post
    As I mentioned above Shimano sells 12x27 10-speed cassettes that do include the very useful 16T cog. I think I'd find the 16 - 18 jump in your cassette just as bothersome and the Shimano is a straight block from 12 to 17. The 17-19 gap is no problem for me.
    The 2 advantages of my setup compared to the Shimano 12-27 are that I have a 28 cog instead of a 27, and I don't make the 3-tooth jump until 22-25 instead of at 21-24. To achieve this, I start the 2-tooth jump one earlier, at 16-18 instead of 17-19, but this seems like a fair trade-off to me.

    I would completely agree with someone who told me they didn't care about these minor differences and couldn't notice them, but it is important to me.

  13. #13
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    Quote Originally Posted by Chris_W View Post
    The 2 advantages of my setup compared to the Shimano 12-27 are that I have a 28 cog instead of a 27, and I don't make the 3-tooth jump until 22-25 instead of at 21-24. To achieve this, I start the 2-tooth jump one earlier, at 16-18 instead of 17-19, but this seems like a fair trade-off to me.

    I would completely agree with someone who told me they didn't care about these minor differences and couldn't notice them, but it is important to me.
    Actually, i prefer big jumps between the larger cogs since when I want a lower gear at that point I want it significantly lower. What I really would like is a 13x28 10-speed as it would include both the 16 and 18 and I have no need for a 12T. Campy makes a 13x29 10-speed cassette which is really great for hilly conditions and does include the 16 but deletes the 18.

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