DIY Articles

DIY Fork Bushing Removal Tool

I have a spare fork that I bought awhile back and am just now getting time to overhaul it (2002'ish RockShox SID SL). I noticed it's starting to wear the stanchions at the bushings so I'd like to replace the bushings. But, this is something I've never done.

While the bushings are cheap (about $15 for the set), the actual RockShox tools to remove and replace the bushings will cost me over $100 and that doesn't include the parts I can't find (bushing install sleeves).

DIY Homebuilt Wheel Truing Jig using Alumaweld rods

I'm calling it a jig because it's really not a wheel truing stand. I've been wanting something to check the runout on my wheels. And, maybe tackle a wheel building project one day.

I had heard about Alumaweld rods and found some on sale at Eastwood for $5.00 shipped. I bought them and put them in my tool chest for some future project. Because of this, I decided to build my truing jig out of square tube aluminum.

Bought a piece of 1" square tube aluminum (36" long) at a home store for $11 and cut it to size.


DIY Project - $55 Bike Workstand

I decided to build my own bike workstand. This blog is the one that inspired me:

DIY Portable Bike Repair Stand

The blog shows a lot of the step-by-step instructions. I'll just show what I did differently.

$7.97 - 3/4" x 24" Pipe
$13.97 - 3/4" Pipe Clamp
$4.00 - 1" Black Tee
$2.52 - 1" x 6" Nipple
$2.52 - 1" x 6" Nipple
$1.87 - 1" Split Ring Hanger
$1.04 - Thumb Screw
$1.18 - Two Hose Clamps
$20.00 - PA Stand (CraigsList)

DIY hubs, single speed, carbon axles,Ti hardware, and carbon hub shell.

Some inspiration for single speed specific hubs.

DIY hubThese were made with carbon hub shell on the front, and carbon axles in both.

The rest of the hardware, is titanium.


Magura :)



DIY Mountain Bike Lights

Riding your bike doesn't have to stop when the sun goes down - get a light! There are a lot of great lights for sale, but some prefer to build their own light*system. Although building your own won't necessarily save you money, there is a sense of pride and satisfaction that comes from building your own light system. Before you can start building your own light, you need to understand the different parts of a light system. A light system can be broken down to: light source, optics, power source and housing.



DIY Zee/SLX to Saint/XT/XTR

Zent mod on a Zee lever

Here you got a mod to turn your Zee/SLX brake lever into a full blown Saint/XT/XTR.

The difference between the above mentioned brake levers, is a tool-free reach adjust, and a bite point adjust.


1) Tool-free reach adjust:

Requires a bit of DIY.

You can make a knob with a drill press or even a simple hand held power drill, with a little elbov grease.

All it takes, is a 2.5mm hex wrench, a small piece of aluminum, and some 2 component epoxy adhesive.


DIY Mavic Freehub Rebuild

I've been having an odd vibration from my CrossMax ST cassette assembly and took a closer look and found the freehub bushing to be worn.

Got bored tonight and decided to rebuild it. Took apart the rear hub Measured the plastic bushing - 25.24mm. Measured the post on the hub - 25.002mm. There was enough play for the cassette to wobble. 

Looked around and found that the freehub is $60+.... being a cheapskate I decided to make a replacement bushing since the lathe was sitting idle tonight.

Started by measuring out the hub, and then went cutting on the lathe.


DIY Headtube Modding: 1-1/8" to Tapered Conversion - Part 2

So....continuing from Part 1

Sanded down the gel coat and got down to the carbon fiber matrix of the head tube, & scuffed up the metal of the headset adaptor.


DIY Headtube Modding: 1-1/8" to Tapered Conversion - Part 1

For you DIY'er's out there...

I figured I was going to get a better fork sooner or later since all the nice forks are tapered, while my 07 SJ frame doesn't accomodate tapered forks. Anyway got a great deal on an RS Revelation XX Wc fork during black Friday and all the parts got here.

Time to get to work....

Designed and made a bottom headset adaptor this morning on my lathe.