Wednesday, September 14, 2011

Journey of the Boardwalk: Part 13 - Dahon Boardwalk TT

Disclaimer: Major upgrade poison ahead! Read at your own risk!
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Ever looked at the Dahon Speed Pro TT, Vector X27 or the Verge X30 and wish you had the bullhorn handlebars? Now you can! With the correct components and some mechanic skills, you can install bullhorns on almost every Dahon folding bike. The bike will still be foldable, using the folding method described in an earlier post.

Advantages of bullhorn handlebars over standard flat bars:
1) More hand positions for better comfort and versatility, especially over longer rides.
2) Longer reach is possible, especially for people with longer upper bodies.
3) More aerodynamic when certain hand positions are used.
4) Brake and shift using the same levers, and reap the ergonomic benefits of the Shimano Total Integration (STI) levers.
5) More natural hand position (palms facing each other) when holding the sides of the bullhorn.

With all these in mind, I set about gathering the components that I needed for the upgrade. In fact it took me more than a month to gather all these parts. Needed to do some research and ask around too for advice. No hurry to do so since I can ride my bike in the meantime anyway.

Components required:
1) Shimano Tiagra 9 Speed STI Levers
2) Shimano 105 RD
3) Kinetix Pro TT bullhorn, clamp size 25.4mm
4) Inner cables and cable housings - LONG ones for the rear brake and rear derailleur
5) Travel Agents by Problem Solvers
6) Tektro Cyclocross brake levers
7) Lots of cable ferrules for covering the cable housing ends

The hardest component to find were the STI levers, it is difficult to find 9 speed ones nowadays. 105 and above level are all 10 speed already. Finally found a pair of second hand Tiagra levers from Togoparts after some time! Taken off a new bike so they are in great condition.


Previously I was using the SRAM X9 shifters with the X9 rear derailleur. Since I will be switching to Shimano STI levers, I will need a compatible Shimano RD. Once again Togoparts to the rescue! Second hand Shimano 105 RD, from the older 5600 series. No problem, black colour can already haha.

Most of the time, the STI levers are paired with caliper brakes, so that the cable pull when braking is compatible. However, I cannot mount caliper brakes on my Boardwalk, as there are no proper caliper brake mounts and also because the caliper brakes will intefere with the fenders. Caliper brakes are possible! Check out the next part of the series here.

In order to overcome this incompatible cable pull issue, I got these Travel Agents from a company called Problem Solvers. What these things do is to alter the pull ratio of the cable, such that the STI levers pull enough brake cable to activate the V-brakes properly. Without them, the V-brakes will feel very spongy and the brake pads will need to be very close to the rims.

To further complicate the upgrade, I decided to add cyclocross brake levers! (No challenge if the upgrade is too simple! LOL) These brake levers are mounted near the middle of the handlebars, and goes between the main STI levers and the brake calipers. They allow braking even when holding the middle of the bullhorns.

First step is to remove all the components on the handlebar, so that I can swap the handlebar! Not easy because I will also need to loosen all the cables and pull out all the cable housings. I cannot reuse the cable housings or cables because they will be too short to route the cables on the bullhorn handlebars.


After this, I needed to open up the chain so that I can remove the current X9 RD. On the SRAM chain that I am using, there is a Powerlink that can be opened up by hand. However, I found it difficult to open by hand most of the time, because it is quite tight and also because I have to work against the chain tension.

Got the KMC Missing Link Chain Pliers and a X-Tools Chain Connector Aid from CRC.

Hook the 2 ends of the chain connector aid around 2 chain links, such that there is no chain tension across the Powerlink. Squeeze the side plates of the Powerlink together (not shown), and use the pliers to push the 2 ends of the Powerlink together.

With the chain pliers, it is very easy to open the Powerlink! Also, the chain connector aid helps to remove the chain tension before opening the link, and holds the chain for you after opening the link! Simple but really useful tools, saves you from sore fingers and dirty hands.

Time to install the new components! See the new bullhorn, STI levers and Cyclocross brake levers! The gold coloured stem is no longer required to extend the reach.

Running the brake cable housing out from the STI levers is not easy, as the cable housing needs to come out at an angle, and then turn sharply to run along the handlebar. This causes more friction for the inner cable. A short section of housing is laid from the STI levers to the cyclocross brake levers, and then a longer housing all the way to the brake calipers. The inner brake cable runs all the way through everything to the brake calipers.

The inner brake cable first loops around the smaller circle, then around the larger circle. This results in the short pull of the STI levers being converted into a longer pull suitable for the V-brakes.

Setting up the shifter cable is much more straight forward, coming out the side of the STI levers and going to the RD.

Before I wrapped the bar tape, I went for a test ride around the neighbourhood, to finalise the positions and angles of the levers. This has to be done before the bar tape is wrapped, else adjustments would be almost impossible.

Wrapping the bar tape also takes quite a bit of skill. Not just anyhow wrap in any direction you like, you actually need to wrap it properly if you want it to last. Check out the youtube link here.

Note the interesting rotating bell on the left bar end, originally from Bike Friday!

Managed to fit my two front lights and cyclecomputer on the bullhorn!

So far have not had any problems with the bullhorn bars. Initially I was worried that the clamp in the middle might not be able to hold the bullhorn properly, allowing it to rotate if I placed weight on the handlebars. But it has been rock solid so far, no slippage at all.

Lastly, a picture to wrap up this wonderful upgrade!

Will be discussing the hand positions possible on the bullhorn handlebars in a future post. Stay connected and check back often!

59 comments:

  1. Interesting solution. Wouldn't it be more elegant to install something like Tektro TT reverse brake levers on the bullhorns and keep SRAM twist shifters? I don't like the look of the now-useless brake hoods on this build.

    ReplyDelete
  2. Hey thanks for the input! hmm but how and where do you install SRAM twist shifters onto those bullhorns? I have never seen anything like that haha.

    Anyway, this was modeled after the Dahon Speed Pro TT, that's why the setup is like that.

    Yeah the brake hoods are not used in this setup. but there are still multiple hand positions possible with this, 5 in fact. Will be reviewing the actual ride feeling and also the hand positions soon, stay tuned!

    ReplyDelete
  3. Hey I posted the first comment. Nice blog post! I'm curious about how your bike rides. I see where you were going with the Speed Pro TT look.

    Question for you:
    Is the issue with 25.4mm bullhorns and SRAM twist shifters that the bullhorns are too wide to fit them? Shouldn't they fit in their standard position on the handlebar itself (not on the horns)?

    I'm thinking of going with the 25.4mm bullhorn, Tektro reverse brakes (hopefully they fit in a 25.4mm bar...) and SRAM twist shifter.

    I don't have a front derailleur on my Boardwalk. I was thinking of upgrading the drivetrain at some point, but I don't know if I can find a front derailleur with a clamp that's wide enough for the Boardwalk's oversized tubing...

    My boardwalk is an older 6 speed freewheel model, which I upgraded to 7 speed cassette when I built a new super-strong touring rear wheel).

    ReplyDelete
  4. the twist shifters will not fit in the usual place, because you can't fit it around the bends!

    if you decide to use flat bar components, you need to take note of the diameter of the handlebar. A normal flat bar has a diameter of 22.2mm, while the bullhorn I have has a diameter of around 24mm.

    If you want to add a front derailleur, you will need an adaptor of 40mm clamp size, and put on a brazed on fd. check out www.thecyclopedia.com. they are out of stock for the adaptor currently, but you can email them to check.

    ReplyDelete
  5. Thanks Steve, you're the Dahon mod expert in my mind! I looked through the whole blog --- wow!!! It was an investment, but you have your bike built to your spec, which is cool! You also helped a lot of others trying to mod their Boardwalks...

    Unfortunately, I couldn't locate the 40mm derailleur clamp anywhere online. I'll try contacting the site you suggested.

    Hey, I've seen some people post about attaching a regular road bike threadless stem to Boardwalk's handlepost (just under the clamp on the top). They then run a regular road bike handlebar. Is this feasible, what do you think? Some people even saw off the clamp on top of the handlepost, but I wouldn't go this far...

    This setup is attractive to me, as it would allow more of an aerodynamic riding position, and the flexibility of drop bars, instead of bullhorns...

    ReplyDelete
  6. well some people have swapped the current top half of the adjustable handlepost for a tube. this tube will then act as a steering tube, you can attach a stem and whatever handlebar you want then.

    great to hear that you enjoy reading my blog!

    ReplyDelete
  7. hello
    I decided to post them in your blog.
    I upgraded my Dahon Jetstream XP
    following your posts. thank you very much for all the pictures and followed your upgrade. one question, for brakes ADDITIONNAL, exactly how did you go, could you give me a diagram, just cut the sheath? short, I did not find picture describing how to proceed?

    sorry for my english..

    A. from France

    ReplyDelete
  8. Hi I suppose that you mean the Cyclocross brake levers that I installed?

    Basically how it works is that these cyclocross brake levers move the brake housing, extending the brake housing. This effectively shortens the inner cable which activates the brakes.

    So what you have will be 1 continuous inner cable, and 2 sections of brake housing. The first section runs from the road shifter to the cyclocross brake lever, while the second section runs from the other side of the cyclocross brake lever to your brakes.

    For more details you can check out this post. http://www.bikeforums.net/showthread.php/120164-How-to-install-Specialized-Road-Brake-Lever-Extensions

    Hope this is useful!

    Regards,
    Steve

    ReplyDelete
  9. Hi" I must say I really like your upgrade to the bullhorn bar. I would like to enquire, I'm currently riding a Brompton P type and like to have the stock handlebar changed to something like a bullhorn or drop bar. Wonder if you have experience something like that with Brompton or know if any local bike shop in Sg that is capable of doing such mod for Brompton.

    ReplyDelete
  10. A Brompton is designed to fold very compactly, if you install bullhorn or dropbar then you cannot fold the bike properly. It totally defeats the purpose of using a Brompton.

    ReplyDelete
  11. Hi,
    What is the price for all the components?
    I want to do the same thing but it seems too expensive !
    Thanks !
    (From France (that explain a little why my english is bad :P))

    ReplyDelete
  12. it's hard to give a price for these, but you can use chainreactioncycle.com for a rough price check

    ReplyDelete
  13. steve,
    may i know the length of the bull bar?
    is it 42mm or 47mm?

    tqvm

    ReplyDelete
    Replies
    1. i think it is probably 42 or 44cm wide. 47cm is too wide to use comfortably.

      Delete
    2. hey steve, where do u find ur Kinetix Pro TT bullhorn? The bullhorns i can find online are
      either 26mm or 31mm. My Dahon P8 also using a
      25.4mm stem so im just wonder where can i find a
      25.4mm bullhorn

      Delete
  14. try Mybikeshop or thecyclopedia.com. 26mm bars will still fit though.

    ReplyDelete
  15. Hello, I thoroughly enjoyed your articles. Could you please tell me where to get the Tektro Cyclcross brake levers?

    Thanks so much!

    ReplyDelete
    Replies
    1. you can find them on chainreactioncycles.com. be sure to check the diameter of the bar at the portion where you plan to install the levers, as the handlebar does not have a uniform diameter. get the correct diameter clamp for the brake levers.

      Delete
  16. Interesting.
    BTW where can I buy the Kinetix Pro TT bullhorn, clamp size 25.4mm? Thank you.

    ReplyDelete
    Replies
    1. hard to find nowadays, dunno if Mybikeshop will bring more in. can try thecyclopedia.com.

      or just get any 26mm bullhorn, that is not carbon. it will also fit. I using 26mm drop bar in the clamp with no problem.

      Delete
  17. Hi Steve,

    I'm thinking of upgrading my Speed D7 to a Bull horn configuration. Apart of the RD mounting bracket, RD, 9/10 Cassette, Chain, What else do I need to change? (Shifters, Brake levers, Calipers?) Currently using avid digit 7 caliper n levers. Any recommended parts? Parts need not be the best in the market.

    ReplyDelete
    Replies
    1. You will also need shifters, plus a FD adaptor and FD if you want to have front shifting also.

      Best to get caliper brakes as they work better with the road shifters. V brakes do not work well with road shifters. Tektro R559 are the only ones I know with arms that are long enough to reach the rims.

      Best to get components as a set so that they match nicely. for 9 speed, you can use Sora 3500. For 10 speed, you can use Tiagra 4600. Please don't use shifters with internal cable routing as they are not good for bullhorns.

      Delete
  18. Hi Steve,

    You ever come across bikes with bull horn but no front shifting? So I will need a SORA/TIAGRA RD,Cassette,FD,FD Adaptor, Caliper brakes. The brake lever need to remove?

    ReplyDelete
  19. Btw Steve,

    Shimano 105 5700 can be use?

    ReplyDelete
    Replies
    1. If you don't intend to have front shifting, you will still need the shifters as they are also the brake levers. Sora 3500, Tiagra 4500 or Tiagra 4600 are all OK. You cannot use 105 5700 as the internal routing of the shifter cable means poor routing on a bullhorn and will not shift properly.

      To list out the components fully, you will need:
      -Bullhorn bar (25.4mm centre clamp diameter)
      -A pair of shifters such as those mentioned above, with external shift cable routing.
      -Cassette
      -Chain
      -RD hanger
      -RD
      -Tektro R559 caliper brakes
      -Aican brake shoe extender
      The brake shoe extended is needed as the brake pads sometimes cannot reach the rim even with the long reach calipers. You can find them on Taobao.

      http://handsonbike.blogspot.sg/2012/05/caliper-brakes-and-stem-for-vitesse-p18.html

      Optional:
      -FD Adaptor
      -FD
      -Compatible crankset
      For best performance you should also change the crankset to a 9/10 speed crankset, as the stock D7 crankset isn't very good.

      Lastly, what exactly do you mean by "brake lever need to remove?"

      Delete
  20. Hi Steve,

    Apologise for my ignorance. I didnt know that the shifters also act as brake. Thats why I asked whether the avid dial 7 levers need to be remove or not. Now I am clear of the components require. Thank you so much. Seems to be tedious thing to upgrade. Btw, I am using 105 crankset now.

    ReplyDelete
  21. Hi Steve,

    Drop bars shld be able to use the 105 groupset right?
    Will still need the extended tektro caliper brakes also?

    ReplyDelete
    Replies
    1. Drop bars can use the 105 shifters as the routing is meant for drop bars.

      You will still need the Tektro brakes and the brake shoe extenders.

      Delete
  22. Hi Steve,

    Sora 3400 can be use for bull horn? 105 5600 can be use for drop bar? Will there be issue if i mix and match these 2 groupsets?

    ReplyDelete
    Replies
    1. Sora 3400 cannot be used as the release lever is by thumb only, cannot work on bullhorn. 105 5600 can be used. But cannot mix as Sora is 9 speed and 105 is 10 speed. Just get a whole groupset and it will be fine.

      Delete
  23. Hi Steve,

    Thank you very much. Time to pick up some mechanic work from you.

    ReplyDelete
  24. Hi Steve,

    So if I do not need front shifting, I do not need to get the FD and FD clamp right? Still workable? Drop bar needs an extra extension stem? eg. (Lite Pro)For me is Bar, RD hanger,RD,Chain, Shifter, Tektro 559. Any other hidden items, cost?

    ReplyDelete
    Replies
    1. If you don't need front shifting, you obviously don't need the FD adaptor or FD. No problem there.

      Not necessary to use the LitePro stem unless you want to vary your handlebar position. You can install the drop bar on the current handlepost, using the current clamp.

      Don't forget the cassette too. If you plan to do the upgrade yourself you will also need the inner cables for the shifter and brakes, and also the outer casings. And not forgetting the tools.

      Delete
  25. Hi Steve,

    I do not know how to do the mechanic work. Have to leave it to the bike shop. Will try to observe and pick up the skill from them. Thanks for all your advice.

    ReplyDelete
  26. Hi Steve,

    The Drop bar mounted on the clamp alone is it wierd? As in no 100mm stem to extend the drop bar forward abit. Is it uncomfortable or too near?

    ReplyDelete
  27. Mounting the drop bar directly is correct. You must understand that the mounting may look different from full sized bikes, but the geometry is similar. The flat bar also does not have a stem to move it forward but it is OK. The drop bar also extends forward so the reach will be longer than a flat bar.

    ReplyDelete
  28. Hi Steve,

    So if i want the drop bar further infront, i can always add a Litepro extended or change to a 5 degrees tilt handle post right?

    ReplyDelete
    Replies
    1. Yes you can always add a LitePro stem to adjust your reach. As for handlepost I think you just got to use the standard type, don't think you can find any handlepost with a different tilt.

      But if you want to use the LitePro stem, it would be easier if you decide if you want it or not, before you fix up the shifters and bar tape. If not, it will be very troublesome to add the LitePro stem, because you will need to remove all the bar tape and shifters before you can put in the stem.

      Delete
  29. Hi Steve,

    The drop bar 40/42/44cm does it makes alot of difference? Ot its just
    Personal preferences?

    ReplyDelete
    Replies
    1. not a lot of difference I think. Google to see how to choose a suitable handlebar width. Best is to try out the width at a bike shop or on a bike.

      Delete
  30. Hi Steve,
    I am currently riding a stock tern link P9. I like the bullhorn setup alot and would like to know what components do I need to change and get in order to have the mechanic help me install on it.

    Thanks

    ReplyDelete
    Replies
    1. You will need the following components:
      1) Bullhorn bar with centre clamp diameter of 25.4mm
      2) LitePro Stem as you can't install the bullhorn directly onto the handlepost
      3) Tiagra 4600 2x10 speed road shifters
      4) Tern RD adaptor
      5) Shimano 10 speed road RD
      6) LitePro FD adaptor
      7) Shimano double road RD
      8) Shimano road 10 speed cassette
      9) 10 speed road chain
      10) 10 speed road double crankset

      Problem will be the brakes. I would suggest fitting Tektro R559 caliper brakes on as that is the best solution to work with the road shifters.

      Delete
  31. Thanks. I read from ur other post that tern does not have a RD adaptor to fix the shimano rd?

    ReplyDelete
    Replies
    1. There is now a new Tern RD adaptor, launched a couple of months ago

      http://www.premiumbikegear.com/ternbicyclesgear/extras.html

      Delete
  32. Is this set something I can look for?

    http://item.taobao.com/item.htm?spm=a2106.m5221.1000384.10.iNU7V2&id=13273708423&scm=1029.newlist-0.bts1.0&ppath=&sku=&ug=

    The price is about 406sgd before shipping.

    Thanks again!

    ReplyDelete
    Replies
    1. Yes the set seems good. You can use every component except the caliper brakes.

      Delete
  33. Hi steve
    I'm having trouble to find cyclocross brake lever with the diameter of 25.4 as i am using drop bar. Will it fit if i get the brake lever with the diameter of 26mm?

    ReplyDelete
    Replies
    1. The brake lever with clamp diameter of 26mm will also work. You just need a very thin piece of shim to make up the difference in clamp size and handlebar size.

      Delete
  34. What is distance between STI small upshift lever and bullhorn side? Ask because I installed SRAM road combo shifters to bullhorn and this distance is too small.

    ReplyDelete
    Replies
    1. What do you mean by the distance is too small? What is the problem with using the SRAM shifter on the bullhorn bar?

      Delete
    2. This comment has been removed by the author.

      Delete
    3. Now i know what you mean. Seems that the SRAM shifter cannot be used on bullhorn bars due to the different design. You have to use Shimano road shifters if you want to use them on bullhorn bars.

      Delete
    4. I solved a little this problem by bending ends of handlebar. Now I can use brakes and shifters. But again have some small problems.

      http://goo.gl/MUap06

      With brakes Tektro R365 I have not enough brake power even if I adjust brake pads as close as possible to wheel rims.

      And due to very short diameter curves when shifter cables leave shifter I have no constant shifting from gear to gear, sometimes it shifts fine, sometimes shifts-downshifts with skipping one-two gears...

      I think in my case it's better to buy normal road bicycle handlebar. It solve at least cable jamming when leave shifters...

      Delete
    5. From what I see, after bending the bullhorn bar, the bent area has crumpled and it has been severely weakened. Please do not use the bullhorn bar for your own safety.

      If you use the Shimano Tiagra ST 4600 shifters with external routing, it will shift well. The problem is not with the handlebar, it is with the choice and type of shifter you are using.

      Delete
    6. Completely assembly my folding bicycle with bullhorn and SRAM Apex shifters. Shifters works fine, both front and back. But brakes with Tektro R365 works not so good as expected, I think main problem here is different brake cable pull of SRAM shifters compared to shimano STI shifters. Since that time braking power is very weak, much better on front, but completely unreliably on back wheel.

      If you have Skype or Line I can describe it more with images. Mine is joshhhab for Line and lindows_by for Skype.

      Delete
    7. Since you can't really use other brake calipers or brake levers, you have to upgrade the other components to improve the braking power.

      You can start with SwissStop brake pads which are very good brake pads. I also used SwissStop brake pads on my bullhorn bike to improve the braking performance.

      Another way is to use good quality brake inner cable and outer casing to minimise frictional losses. The new Shimano polymer brake cable will be good for this.

      Delete
    8. Since you can't really use other brake calipers or brake levers, you have to upgrade the other components to improve the braking power.

      You can start with SwissStop brake pads which are very good brake pads. I also used SwissStop brake pads on my bullhorn bike to improve the braking performance.

      Another way is to use good quality brake inner cable and outer casing to minimise frictional losses. The new Shimano polymer brake cable will be good for this.

      Delete
    9. Finally installed road handlebar

      https://flic.kr/p/serofq

      Delete

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