|3iker

I'm just wondering is it possible to mix and match the cogs b/t different cassettes. I have 2 sets of Shimano cassette. According to Sheldon Brown, it is ok. But anyone has thoughts.

10 Wheels

Should be ok.

|3iker

^ Even if they are of different model range within the family? I have a hg50 donor cassette that I like use for my CS6500.
Cogs Part #s seem to differ for both cassettes. They sure look the same to me.

Al1943

Generally OK but there are some limits on what you can do. Upper level groups like Ultegra, D-a, Record, etc. Have the larger cogs pinned together on a cmmon carrier. These cannot be used as individuals if separated because the splines are on the carriers. And, of course, the cog spacing must be maintained.

DannoXYZ 

Also be careful of different cog-thicknesses. You can mix and match if the cogs come from the same number of speeds. But 8-spd cogs are thicker than 9-spd and 10-spd is thinner still. If you mix them across different speeds, you need to shim the spacer with additional 0.1mm spacer if a 9-spd cog is used with 8-spd cluster. Using an 8-spd cog on 10-spd cluster would require grinding down some spacers to remove some thickness to compensate for the thicker cog.

2_i 

Things can be even more subtle in that the tips of teeth may be positioned differently within the thickness of a cog for the same speed. In the end, a custom cassette requires some fine tuning with spacer thickness to arrive at optimal shifting. Get some extra spacers such as from different speeds when going ahead with the project. BB spacers fit onto the cassette too. Be prepared to cut out a spacer ring out of a soda can. Finally there is a guy on Ebay who offers custom spacers.

Al1943

Exactly which cogs are you trying to change?
6500 is Ultegra 9-speed. I have quite a bit of experience mixing cogs on 9-speed Ultegra and D-A cassettes.

badamsjr

I have been switching SOME cogs on SRAM 9spd cassettes. I like low gears, so have 11-32 and 11-34 cassettes, which are not ideal (wide spacing, and more 'top end' than I need), so I have switched the smaller cogs around (the ones NOT pinned together) to get a 12,13,14,16,18,21,24,28,32 setup. The stock setup is 11,12,14,16,18,21,24,28,32. Not a big change, but it gives me more even spacing, while keeping the low gears. Still working on getting the right 34 setup.

Shimano cassettes are similar to SRAM, so I think if you work within one speed (9spd, 10spd, etc.) you should be OK.

Chris_W

It can work very well. I'm currently using a custom 12-28 cassette made up of 3 separate cassettes and it shifts very well even at the junctions between cassettes. On the other hand, I once removed the 16-tooth cog from a 12-25 cassette to customize that, and the 15-17 shift then did not work very well.

My current combination is 12-13-14-15-16 from a 12-25 Shimano 105, then 18-20 from a 16-27 Shimano junior-racing Ultegra, then 22-25-28 from an 11-28 SRAM 1070. I've been surprised and happy with how well it performs and the gear range and spacing is ideal. No-one offers a stock cassette with such a combination, so this custom route is the only way to do it. I used many of the leftover cogs in cassettes for other bikes.

DannoXYZ 

I've had this happen as well. What is required in cases like this is to grind off the wide spline on the 15t cog and rotate it one spline over to match the release-teeth of the missing 16t cog. I find it easier to customize the smaller cog of a pair because it causes less interference with the smaller cogs on the other side than larger ones. That is, it doesn't interfere with the 14->15t shift as much as the 17->19t shift.