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  1. #1
    Senior Member guybierhaus's Avatar
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    Old Guys Bike Project

    Entry 1 - Start

    I致e started a project to build a bike. It is nothing special, a used 1999
    Cannondale R800 frame and carbon fork from ebay. Probably paid too much,
    but liked the color. My reason to build is to understand better how todays
    bikes go together and to make something that fits my idea of what I want to
    ride. I also like to wrench but I知 tired of working on my car. I have some
    ability as a back yard auto mechanic and formal training by the USMC as a
    helicopter mechanic. As a result I have many tools. I知 presenting my project
    here with the 50 plus forum as that is where I hang out. Not expecting to get
    into too much of the mechanics; although you all can offer your 2 cents, should
    you seem compelled.

    The bike will be thrown together with lots of Nashbar parts. I知 using the
    Nashbar compact double crank and a Nashbar extra high stem. I will be
    building with a flat bar and picked up new Deore shifters/brake levers on ebay.
    Got a long cage (whatever that means) Deore rear deraileur, suitable for the
    11t x 34t cassette I ordered. So will have lots of gear range. Wheels are
    currently Alex 450, my extra set from my Trek 1000. I知 at 255 lbs, so will be
    staying with 36 spokes for awhile. I did want to fit 28m tyres to hopefully
    permit some riding on packed trails, although I prefer roads.

    My immediate problem is a name for what I知 building, and I believe you guys
    and gals may have a suggestion, FUBAR is not acceptable. I thought of
    R800GT, but GT is so clich. Maybe Yellow Jacket, taking in account the color,
    although that doesn稚 strike my fancy as I致e been stung by them too often.
    Attach starting photo, missing parts on order. Brakes I知 still trying to snag a
    pair at ebay.
    Last edited by guybierhaus; 02-18-07 at 01:06 PM.
    BierHaus Bertolette Road Bike, built 2007
    BierHaus SRT Trail Bike, built 2010
    Fuji Mt. Pro - 2007

  2. #2
    Geezer Member Grampy's Avatar
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    It's not ready for a name yet...... When it's ready, you'll know the name.
    Carpe who?

  3. #3
    Senior Member
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    Quote Originally Posted by Grampy
    It's not ready for a name yet...... When it's ready, you'll know the name.
    All true, but that won't stop us from jumping all over a naming contest in here...

  4. #4
    Seor Wences jwbnyc's Avatar
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    Yellow Jacket.


  5. #5
    I need more cowbell. Digital Gee's Avatar
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    Cheeze Whizzzzzz
    Visit my blog! The Leadership Almanac
    2012 Masi Evoluzione
    2009 Specialized Globe Vienna 2

    Proud member of the original Club Tombay

  6. #6
    Senior Member
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    "Maillot" something...

  7. #7
    Senior Member guybierhaus's Avatar
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    Entry - 27 Aug 2006

    Introduction and parts picture out of the way, now time to do some work. I
    received frame a few weeks ago, very fast shipment. I of course did no
    research before buying, I liked the color and it was a Cannondale. Initially
    disappointed with a 1 inch treaded steerer, but got over that. But I was set
    back when I realized frame had downtube friction shifters, I wanted flat bar
    mounted index shifting. The problem was downtube had no cable stops for
    index shifting cables. Thanks to Bike Forum, I searched the problem and found
    a solution, picture attached. These cable stops attach to friction shifter
    mounting studs, so they are installed. Next up is to install the Nashbar
    headset. I read no directions. Set parts in proper place, manage to catch some
    threads on steerer tube and crank everything together with ratchet and proper
    socket. Directions refer to a special tool...O well, maybe next time. Bottom
    Bracket is next, but believe I値l read directions for that, installation is not so
    obvious.
    Last edited by guybierhaus; 02-18-07 at 01:06 PM.
    BierHaus Bertolette Road Bike, built 2007
    BierHaus SRT Trail Bike, built 2010
    Fuji Mt. Pro - 2007

  8. #8
    Banned. Gary Diego's Avatar
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    Quote Originally Posted by Big Paulie
    "Maillot" something...
    Maillot Whizz?

  9. #9
    Lincoln, CA Mojo Slim's Avatar
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    My favorite color scheme, so I know I'm gonna like it.
    Truth is stranger than reality.
    '96 Giant ATX 760 MTB
    '01 Bianchi Eros
    '05 Giant OCR Llimited Carbon Fiber + upgrades

  10. #10
    just keep riding BluesDawg's Avatar
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    "Hand-number"
    Whatever blows your skirt up if you don't like drop bars, but at least give some thought to getting a bar that sweeps back enough to put your wrists in a natural position. Maybe something like these:
    The more you ride your bike, the less your ass will hurt.

  11. #11
    Never trust a smiling dog
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    Quote Originally Posted by guybierhaus
    I did want to fit 28m tyres to hopefully
    permit some riding on packed trails, although I prefer roads.
    Looking at your pic, those tires look very close to the rear brake bridge. On many bikes 25 is about as large as you can go. Depends of course on the tire manufacturer's sizing as well.

  12. #12
    Senior Member guybierhaus's Avatar
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    I just checked that since you mentioned. Looks like lots of room at break bridge, but not so much at BB. A true 28m should clear. Current wheel/tyre is 25m and clears even with the bend in it. (broke spoke). This is one of those surprises I got a few months ago. Thought within the same brand, Shimano, all things were interchangeable. Thought I'd install back wheel from 7200 hybrid onto trek 1000 to try out the 11 x 34 cassette. Wrong. No room for 35m tyre and to my surprise the Sora deraileur will not feed a 34t cog. Never knew DE's had gear diameter limits.
    BierHaus Bertolette Road Bike, built 2007
    BierHaus SRT Trail Bike, built 2010
    Fuji Mt. Pro - 2007

  13. #13
    Senior Member guybierhaus's Avatar
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    Quote Originally Posted by BluesDawg
    "Hand-number"
    Whatever blows your skirt up if you don't like drop bars, but at least give some thought to getting a bar that sweeps back enough to put your wrists in a natural position. Maybe something like these:
    I will give that some thought. Everything I have is now flat bar, but even with bars ends I do find myself around 20 plus miles looking for another place to put hands. If only I could balance well enough to ride with no hands. Don't know if it's age or weight that has reduced ability to balance.
    BierHaus Bertolette Road Bike, built 2007
    BierHaus SRT Trail Bike, built 2010
    Fuji Mt. Pro - 2007

  14. #14
    Senior Member
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    the "Golden Cannon"...
    centexwoody
    They're beautiful handsome machines that translate energy into joy.

  15. #15
    Let's do a Century jppe's Avatar
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    That looks like a pretty sweet frame and setup. I know it will be a special bike when it's all said and done. The best way to learn is to roll up your sleeves and dig in......You have certainly done that with this one but that's terrific that you have the ability to sort things out. Good luck with the build!!

  16. #16
    Senior Member NOS88's Avatar
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    Impressive project; one worthy of taking on. As a possible name, might I suggest "Old Yeller"?
    A conclusion is the place where you got tired of thinking. - S. Wright

  17. #17
    Older I get, Better I was velonomad's Avatar
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    Being yellow and an over 50 bike. you could call it "Xanax"

  18. #18
    Senior Member dauphin's Avatar
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    "Old Yeller"

  19. #19
    just keep riding BluesDawg's Avatar
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    Quote Originally Posted by dauphin
    "Old Yeller"

    ding! ding! ding!

    Whatever you name it, enjoy building it and riding it. Having built and restored a few, I can't imagine ever being satisfied with a pre-built bike again.
    The more you ride your bike, the less your ass will hurt.

  20. #20
    Senior Member
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    How about "My Cannondale" A bike that pretty doesn't need an introduction.

  21. #21
    Love to ride! starship's Avatar
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    I'm riding a 2003 R800 now, and IT IS A BIT UNSTABLE with no hands. I can do it, but only if cranking at high speed.

    But I'm also over 50+. humm.

    OLD YELLOW, love it!
    2010 Jamis Allegra 2X
    God loves you, and God loves me, Even if I do cause his over time!

  22. #22
    Senior Member guybierhaus's Avatar
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    The names are getting better. Golden Cannon, maybe yellow cannon or banana cannon. Old yeller, I don't know. For me bike isn't old. maybe Mellow Yellow. Actually I'm stuck with banana.
    Maybe Cycle Banana. ByBanana. Bad Banana

    Entry 28 Aug 2006

    Directions with bottom bracket were useless. Said in part "to grease crank bolts. Installing a BB is a specilized job, take to LBS." Went online and got some tips. Established the flange goes on crank side, and what stumped me a bit, the threads on left side of BB appeared attached to BB case, couldn't figue how I was gonna thread this monster in. But discovered they come off with a firm twist and pull. The online directions referred to these threads as a lock ring. One heck of a fat ring. So now that I was feeding parts with threads in from both sides, it made more sense. Online tips suggested plumbers teflon tape on threads, and so it was done. Have enough experience to know I must be careful with fine aluminum threads, less I cross thread and ruin everything. But must say here, putting new parts together is a whole lot easier then taking apart old parts. Could actually hand thread in BB 3 or 4 turns. Anyway bolted on crank with the greased bolts, torqued to one elbow click. Decided to install stem and the flat bar I have. Mounted seat and wheels, so it actually looks like a bike. Rear cassette and chain still on order. Looking at bike I definately have to get black brake calipers. And probably other all black pedals. "Darth Yello" Now those little silver cable stops are gonna bother me.

    Another surprise. Existing Trek 1000, size 56cm, son in law says it looks too small for me. I have short legs so went for stand over height. Trek is 31 1/4 inchs. With Cannondale thought I'd try one size bigger and got a 58cm. Stand over height on Cannon is 32 3/4 inch. It would appear between manufactures there is significant differences between size dimensions. I may have to ride bike with 1/2 inch shoe lifts.
    Last edited by guybierhaus; 02-18-07 at 01:06 PM.
    BierHaus Bertolette Road Bike, built 2007
    BierHaus SRT Trail Bike, built 2010
    Fuji Mt. Pro - 2007

  23. #23
    zum
    zum is offline
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    Lady Finger (as in bananas)? Jaundice? Radiant? Hi watt? Eyecatcher? Saffron? Curious (Notorious '70s Swedish film "I am curious...Yellow")

    that's my lot!
    Last edited by zum; 08-29-06 at 06:48 AM.

  24. #24
    Ol' Paint
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    How 'bout the "Golden Mean"?

  25. #25
    Senior Member guybierhaus's Avatar
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    Entry 5 Sept 2006

    Project pushed aside while I prepared house for Ernesto tropical storm, cut
    grass and actually rode other bike before rain. Was not too impressed with
    Nashbar cassette, looked like it belonged on a Wal-Mart bike, also weighed
    significantly more then the SRAM cassette I replaced. But it was only $20. I値l
    ride the 11 x 32 to see if that痴 what I want, maybe will go back to 12 x 26.
    Had purchased special socket to remove cassette lock ring. NOTE: Real bike
    mechs do not read next line. To hold the cassette I went without the special
    chain holding tool and just wrapped a rag over cassette teeth and held with
    water pump pliers. Water pump pliers work so well on so many things, a real
    must tool.

    Took another break and checked other names for Yellow jackets, and looked
    up names of war planes and choppers. Currently leaning toward Hornet for
    project name. Or more properly Cannondale R800 Hornet.

    Back to work. Mounted shifters and brake units, mounted derailleurs, ran
    derailleur cables, shoved on bar grips, using dish washing fluid as lube to slide
    them on. Bolted on bar ends, then bolted on a typical wire bottle cage, but
    cage just didn稚 look right. Found a carbon cage on ebay, should provide a
    little bling. Although may lose that bling when I put in my Propel water bottle.
    The Propel water wasn稚 that good, but the bottle at 27+ oz.. is great. While
    at ebay, finally just used a Buy it Now and got the Black Shimano 105 brake
    calipers. I知 getting ready to ride this bike and still have no brakes. Finished
    the night with placing a new chain and trying to adjust derailleurs with no
    knowledge of what I was doing. Finally gave up, put bike aside and will read
    directions. The Hornet is looking good.

    After taking attached pic, I just had to test ride. About 50 feet into ride I went for brakes.
    So ride was short, not good dragging feet. Discovered double FD will respond to 3rd shift
    and shifted chain onto crank arm. Will have to fix that. With directions in hand I'm back
    to adjusting RD.
    Last edited by guybierhaus; 02-18-07 at 01:06 PM.
    BierHaus Bertolette Road Bike, built 2007
    BierHaus SRT Trail Bike, built 2010
    Fuji Mt. Pro - 2007

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