I know this was posted 3 months ago but what the heck.. I converted a 1996 Trek 800 to full touring and loaded it with me and all my gear. Total weight including bike was an even 300 pounds. The bike unloaded is 38 pounds, gear was 45 pounds and I made up the rest. On it's maiden voyage from Miraposa to Yosemite and back I logged in 100 miles without a glitch. Here is what I did.

The bike's geometry, chainstay length and tube lengths are VERY similar to the Surly LHT, 26" wheel version. I bought the 800 on Craigslist for 25 dollars, complete but all I wanted was the frame so I took it apart and tossed the cheap components. I then bought a 2001 Fuji mtn bike for its components only and tossed the frame. I transferred the components from the Fuji onto the Trek in a weekend, added racks and lights and better wheels. What I came out with was a very stable bike. It handled well down hills at 40 MPH and up hills fine with the mountain gearing. I used 680mm wide riser bars with Ergon grips and bar ends for hand positions. Ive ridden this bike now for 1000 miles in 60mph wind, pounding rain and the 26" 2.1 tires allow me to hit dirt and gravel roads and stabilize the weight. Longest Ive comfortably ridden in one day was 105 miles. Sure, it's 38 pounds all by itself with racks, but a chro-mo frame isnt 300 dollars worth lighter. (I carry a folding chair when I tour, Im not a weight weenie).

Dont let anyone scare you about building a bike. All you need is the cheaper specialized tools from any bike shop. Knowing how to build a bike inspires confidence on the road, if I to break down at least I would know how to fix/replace. Aside from the color (purple), I love this bike. I may put knobbies on it, remove the fenders and take it off-road and I will never cry if it gets scratched.