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PostPosted: Thu Jan 17, 2013 10:08 pm 
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bad kitty!
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So, another project I got cooking, is to convert a PG990 cassette, to 11-38, eventually maybe even 10-38/40.

So far I have made (ok, I had a guy that works for me do it) the CAD footwork, to do a 38 tooth cog for the rear, and a 36 tooth XX1 style chain ring.
Before everybody starts looking funny at the 36T chain ring, keep in mind this is for a 24" bike, so 36T is not all that big.
I also have taken a PG990 cassette apart, and plan to re-space it to 10 speed.
I'm a little tied up right now, but the plan is to get this going ASAP, as this seems like a nice mod, and would fit my Zee drive train well.

I had him do an assembly, to check clearance of the teeth of the 36T, as that seems to be the big deal about the XX1 style rings.
See attached image.


Magura :)


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11 og 36 tænder og kæde Cl12.jpg [401.83 KiB]
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PostPosted: Fri Jan 18, 2013 12:04 am 
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Very interesting! How about some carbon fiber cogs for the cassette?

http://www.ruckuscomp.com/chilling-out- ... -all-cool/


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PostPosted: Fri Jan 18, 2013 12:10 am 
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bad kitty!
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Sti wrote:
Very interesting! How about some carbon fiber cogs for the cassette?

http://www.ruckuscomp.com/chilling-out- ... -all-cool/


Naah, been there ;)
They were VERY short lived.

For one single road race though, it could be a great solution.


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PostPosted: Fri Jan 18, 2013 3:00 pm 
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Ever thought of replacing the smallest cassette cog with a dual cog plus an extended nut? Just a thought... Could just CNC one out of solid whatever.....

...or would that put the cog too close to the dropout/chainstay.

-S

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PostPosted: Fri Jan 18, 2013 3:45 pm 
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bad kitty!
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Shibiwan wrote:
Ever thought of replacing the smallest cassette cog with a dual cog plus an extended nut? Just a thought... Could just CNC one out of solid whatever.....

...or would that put the cog too close to the dropout/chainstay.

-S



That's pretty much the cunning plan. I will though put it only half way off the cassette.
From what I can tell, that is possible, if made of something adequately strong.


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PostPosted: Fri Jan 18, 2013 5:56 pm 
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Magura wrote:
Shibiwan wrote:
Ever thought of replacing the smallest cassette cog with a dual cog plus an extended nut? Just a thought... Could just CNC one out of solid whatever.....

...or would that put the cog too close to the dropout/chainstay.

-S



That's pretty much the cunning plan. I will though put it only half way off the cassette.
From what I can tell, that is possible, if made of something adequately strong.


Magura :)


....and then we add a 40T cog on the inside by the spokes for 12 speed!

-S

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PostPosted: Fri Jan 18, 2013 6:03 pm 
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bad kitty!
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LOL!

Let's stop around 10 or 11 speed, no? ;)

.......and then again, why not?
Gonna be some nasty cross chaining though.


Magura :)

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PostPosted: Fri Jan 18, 2013 6:23 pm 
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Magura wrote:
So, another project I got cooking, is to convert a PG990 cassette, to 11-38, eventually maybe even 10-38/40.

So far I have made (ok, I had a guy that works for me do it) the CAD footwork, to do a 38 tooth cog for the rear, and a 36 tooth XX1 style chain ring.
Before everybody starts looking funny at the 36T chain ring, keep in mind this is for a 24" bike, so 36T is not all that big.
I also have taken a PG990 cassette apart, and plan to re-space it to 10 speed.
I'm a little tied up right now, but the plan is to get this going ASAP, as this seems like a nice mod, and would fit my Zee drive train well.

I had him do an assembly, to check clearance of the teeth of the 36T, as that seems to be the big deal about the XX1 style rings.
See attached image.


Magura :)


I should steal your attached image since it has the right chain/sprocket dimensions for me to draft out crap. LOL

-S


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PostPosted: Fri Jan 18, 2013 6:24 pm 
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Magura wrote:
LOL!

Let's stop around 10 or 11 speed, no? ;)

.......and then again, why not?
Gonna be some nasty cross chaining though.


Magura :)


LOL you're right. Would be some crazy cross chaining going on.

-S


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PostPosted: Fri Jan 18, 2013 7:07 pm 
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adminkat wrote:

I should steal your attached image since it has the right chain/sprocket dimensions for me to draft out crap. LOL

-S


It would be easier to ask for what you exactly need, as my CAD guy has made all the formulas and what not.

Magura :)

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PostPosted: Fri Jan 18, 2013 7:46 pm 
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Magura wrote:
adminkat wrote:

I should steal your attached image since it has the right chain/sprocket dimensions for me to draft out crap. LOL

-S


It would be easier to ask for what you exactly need, as my CAD guy has made all the formulas and what not.

Magura :)


Naah, got what I needed - everything else is easy with parametric programming (looks like your guy used solidworks)

-S

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PostPosted: Fri Jan 18, 2013 7:50 pm 
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bad kitty!
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Shibiwan wrote:
Magura wrote:
adminkat wrote:

I should steal your attached image since it has the right chain/sprocket dimensions for me to draft out crap. LOL

-S


It would be easier to ask for what you exactly need, as my CAD guy has made all the formulas and what not.

Magura :)


Naah, got what I needed - everything else is easy with parametric programming (looks like your guy used solidworks)

-S


Indeed he does ;)

He has pretty much the whole thing nailed by now, so whatever cog / chain ring, it takes him like 20 minutes to do.
The shape of the teeth, are not the same all the tooth counts.
That's why I had him make a chain, so it's possible to check tooth/chain clearance.

Magura :)

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PostPosted: Fri Jan 18, 2013 9:58 pm 
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Magura wrote:
Indeed he does ;)

He has pretty much the whole thing nailed by now, so whatever cog / chain ring, it takes him like 20 minutes to do.
The shape of the teeth, are not the same all the tooth counts.
That's why I had him make a chain, so it's possible to check tooth/chain clearance.

Magura :)


...and if you model the chain correctly, you can use it in an assembly to check the ramping between cogs.

-S

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PostPosted: Fri Jan 18, 2013 10:01 pm 
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bad kitty!
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Shibiwan wrote:
Magura wrote:
Indeed he does ;)

He has pretty much the whole thing nailed by now, so whatever cog / chain ring, it takes him like 20 minutes to do.
The shape of the teeth, are not the same all the tooth counts.
That's why I had him make a chain, so it's possible to check tooth/chain clearance.

Magura :)


...and if you model the chain correctly, you can use it in an assembly to check the ramping between cogs.

-S


Exactly, that's why i had him make a chain ;)


MAgura :)

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PostPosted: Fri Jan 18, 2013 10:08 pm 
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Magura wrote:
adminkat wrote:

I should steal your attached image since it has the right chain/sprocket dimensions for me to draft out crap. LOL

-S


It would be easier to ask for what you exactly need, as my CAD guy has made all the formulas and what not.

Magura :)


In that case, I should steal your solidworks file. LOL Have him save it in SW 2008 format please :D

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PostPosted: Fri Jan 18, 2013 10:13 pm 
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I'll pass the request.


Magura :)

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PostPosted: Sat Jan 19, 2013 3:56 am 
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btw shouldnt the name be pg990xx (since its 10 spd)

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PostPosted: Sat Jan 19, 2013 9:59 am 
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Shibiwan wrote:
btw shouldnt the name be pg990xx (since its 10 spd)


Naah, mine will go to 11 :D


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PostPosted: Wed Apr 03, 2013 12:27 am 
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Seems the $$1 style rings are becoming available for other crank sets.

http://wolftoothcomponents.com/


Magura :)

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PostPosted: Wed Apr 03, 2013 6:18 pm 
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Magura wrote:
Seems the $$1 style rings are becoming available for other crank sets.

http://wolftoothcomponents.com/


Magura :)


Gotta rush the official HK ones out soon!

-S

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PostPosted: Wed Apr 03, 2013 7:28 pm 
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You'd better kick it into high gear. Raceface is also coming out with XX1 style rings.

http://www.ridemonkey.com/forums/f140/r ... ng-257823/

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PostPosted: Wed Apr 03, 2013 8:26 pm 
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I'm noticing that nobody else is screwing with asymmetrical tooth profiles for the XX1 style single rings. Guess we will be the first?

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PostPosted: Wed Apr 03, 2013 8:32 pm 
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The next natural step: $$1 composite rings :D


Magura :)

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PostPosted: Thu Apr 04, 2013 7:52 pm 
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Magura wrote:
The next natural step: $$1 composite rings :D


Magura :)


Document the process so we can figure out a way to mass produce them (molds etc) lol

-S

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PostPosted: Thu Apr 04, 2013 8:32 pm 
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bad kitty!
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Shibiwan wrote:
Magura wrote:
The next natural step: $$1 composite rings :D


Magura :)


Document the process so we can figure out a way to mass produce them (molds etc) lol

-S


Naaah, I think I'd rather extort you :D


Magura :)

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PostPosted: Thu Apr 04, 2013 9:06 pm 
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Magura wrote:
Naaah, I think I'd rather extort you :D


Magura :)


Fine then. No candy for you!

-S

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PostPosted: Thu Apr 04, 2013 9:07 pm 
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Shibiwan wrote:
Magura wrote:
Naaah, I think I'd rather extort you :D


Magura :)


Fine then. No candy for you!

-S


I'm too fat anyway :D


Magura :)

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PostPosted: Tue May 07, 2013 7:45 pm 
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I got around to machining the PG990 cassette today.
One thing that really surprised me, is how miserable the alignment and tolerances were on the original.
It wasn't like 0.1mm here and there, but rather 0.25mm and the like.....holy crap!
For a cassette that was considered their "top of the line", for a couple of years, I'd say that's minimally exceptional.

So, after getting the whole thing machined, it now runs true. I kinda look forward to see what that brings to the table, as that ought to offer fair tolerances on the derailleur adjustment, and perhaps better shifting.
Just for kicks, I measured the alignment of a XTR cassette as well, it wasn't much better.

Pics to come. It looks rather neat now, being machined and all.


Magura :)

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PostPosted: Tue May 07, 2013 7:59 pm 
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PostPosted: Tue May 07, 2013 8:28 pm 
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bad kitty!
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A pic of the machined parts, and with the first two cogs mounted.

I decided against making it a 10 speed for now, as I figured I would have very limited use of neither a 10T nor a 38T, considering this goes on a very short chain stay 24" bike.
That may change at some point though, as I did prepare a 38T add on.


Magura :)


Attachments:
SAM_1303scl.jpeg
SAM_1303scl.jpeg [ 157.46 KiB | Viewed 10181 times ]
SAM_1302scl.jpeg
SAM_1302scl.jpeg [ 163.5 KiB | Viewed 10181 times ]

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