How to build a World Cup race bike

The CRC/Nukeproof mechanic Dave Garland talks through the spec and build of Lewis Buchanans race bike.

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How to service your Hope Pro 2 Evo rear hub - Hope Technology
This hub features a one piece 7075 aluminium rotor body and pawl carrier. Four pawls engage into a twenty-four tooth steel ratchet which is fixed into the hub shell and is sealed with a frictionless, non contact labyrinth seal. The axle runs on five cartridge bearings.





Nicolai ION 16 - bike assembly
More at http://bikebook.si Complete bike weight: 13,2 kg Info: This time we are assembling the new Nicolai ION16. We start with bottom bracket. Grease the rubber o-ring. Grease the threads on frame and install the bottom bracket outer caps Insert the round shaped spring and with the tool you get with bottom bracket push in the bearings. Heavily grease the bearings and insert the safety spring. Insert the green rubber, black cover cap and rubber o-ring. Push the chain set axle through bottom bracket and tighten crank arm on the other side. Before fork installation, grease the bottom of steering tube and push the crown race all the way down on the steering tube. Grease the head tube bearings on the frame to prevent access of water. Install compression ring, rubber o-ring and cover cap. Then install spacers, stem and head set top cap. Don't forget to install star nut in steering tube. We already had this installed. How to insert star nut, check our video: "How to cut and install a new bike fork". Cassette is Sram XX1 that means it has a thread for installation on free hub. For derailleur installation we have to stretch it and push the lock button so it stays in the extended position. We dismounted the shock to check how the rear triangle moves. Installation of the rear brake calliper. For cable routing and proper length of brake cable we have to remove the hose from the brake. You have to bleed the brakes after hose cutting. Front brake installation. If the brake hose is bent you can fix this with unscrew the bolt on the brake for half the turn or a bit more and adjust the brake while holding the hose. Rear derailleur house routing Shorten the chain to the proper length. Put the chain on biggest chain ring in front and biggest cog so that ends overlap for one full link when we put them together. For measuring chain length do not route the chain trough the derailleurs. Grease the threads of pedals and keep in mind, pedals are left and right. For routing of reverb cable you need to have an extra hose to extend it so you can pull it through the frame. Disconnect the reverb hose from the remote control button and attach it to the extension hose. »Red« Extension you get in reverb stealth package. Now you can push/pull the hose and install the seat post. Grease the seat post before inserting. Secure the cables cut reverb hose to the proper length and reinstall the remote button. At the end check that all the screws are tighten according to the torque values.





How Its Made / Season 23 Episode 13 / Mountain Bikes
And this is how they do it! Not the best frame in particular but the process is the same. Have to admit it takes a couple of long hours to make a proper decent bike.





How to Build a Bicycle
This video will show you how to build a bike starting with just a frame.




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