Iron Horse Build

Discussion in 'Photos & Bicycle Builds' started by buzbikebklyn1, Jun 24, 2009.

  1. buzbikebklyn1

    buzbikebklyn1 New Member

    Here's the bike I'm using for the build-
    2003 Iron Horse Warrior men's 21.5" hard tailed mountain bike frame. I bought the frame off my boss at the bike shop for $30.00. The frame and the seat post clamp are the only original part left of the bike.

    The Rims Are Xtera deep "V" cross section 32 hole models,That were once on a crappy Pacific mountain bike that I found in a dumpster, they were painted yellow but were still true so I cut our the El cheapo hubs and spokes and used Shimano XT disc brake mountain bike hubs front and rear with Buchanan's stainless steel spokes and brass nipples, I used a drop of blue loctite in each nipple during assembly.

    The drive train consists of Shimano 105 road bike and XT parts and an XT 9 speed cassette type gear stack that I had left on the shelves.

    The brakes are Avid BB7 mechanical calipers with 230 mm rotors so i can stop faster than i can get into trouble.

    The fork is the last of the "dumb" rock shock pyslos and is adjustable for ride height, rebound and compression dampening and its got an anti dive lock out.

    The fork is mounted to the frame with an F.S.A. "downhill pig" "A" type sealed bearing head set, this piece is about $40.00 cheaper than the accepted best Chris King and its twice as strong.

    I use a 30 degree 4" stem, 5" riser flat track bars.
    The controls are XT 9 speed quick click trigger shifters with Shimano V brake levers and Oury sticky grips.

    The saddle is a Vetta downhill model that's been recovered in black leather and its more comfortable than it looks.

    All control cables were measured and cut to exact length and the ends were dressed and capped off with allot ferule ends for smooth long term operation.
    Notice the rear derailleur loop... its a metal ball and tube arrangement with a Teflon inner sleeve for precise crisp shifting.

    I've purchased a Jet 66cc(chink80) black engine kit, a Sick bike parts shift kit and pipe and several other parts including custom made Kings chain rings to replace the crappy ones from the shift kit.
    I'm going to document the entire build on these pages.
    I welcome your comments and tips-
    Tommy M.
    Allpictures taken at Mckinley park in Brooklyn NY.
    Last edited: Jun 24, 2009

  2. Happy Valley

    Happy Valley Active Member

    You did a nice job with that. I have to say it's refreshing to see attention to detail and an eye toward quality component groups go into a build. Enjoy the rest of your project.

    (then....down the road.....we'll get ya onto an XTR class engine :devilish:)
  3. Irish John

    Irish John Guest

    Nice bike but the front derailleur cable crosses the seat tube and may cause probs with engine mounting and SBP shofter kit. I reckon you'll need a more comfortable saddle but if all goes according to plan the bike will look great all in black. Riding a MB calls for a more upright posture than ordinary cycling. The high rise bars will help and you can always drop the saddle lower to suit.
  4. buzbikebklyn1

    buzbikebklyn1 New Member


    As i will be useing a Sick bike parts shift kit the front derailure will be removed and the bikes painted deep blue satin.
  5. buzbikebklyn1

    buzbikebklyn1 New Member

    Iron Horse Warrior Build. Part III

    Ok guys... after almost a year of delays,due mostly to the evils of the N.Y.S. DMV, and me not having the time, I've finally got the Iron Horse build going.
    I wont go over her specs again as I've documented that in my first post a year ago.
    Let me apologize in advance for my lousy documentation habits, I just get the building bug and don't stop to take pics the way I should.

    I originally bought a Morini S6-T engine for this bike, but after I hung it in the frame its was obvious that the Italians who designed it weren't concerned about having a big fat down tube directly in front of the exhaust port, I decided to save my little Italian gem for a better frame that was designed around it.
    (watch out for this one guys, its gonna be a monster)

    I love this bike...its still one of the sweetest handling aluminum hard tail frames I've ever owned.
    Since I built it in the summer of 2003 its had 3 different rack mount friction drives on it and has survived many many thousands of miles...
    A few dings and scratches, a nasty chain bite to its right chain stay and I stripped out the mounting holes for the rear disc brake adapter and had to re tap them for over sized grade 8 bolts.
    Not to bad for an old war horse.

    Since the heart of this build will be a massaged
    Sick Bike Parts heavy duty shift kit, a milled slant head/polished combustion chamber/port matched cylinder/intake/exhaust ported GT5R engine with a tuned S.P.B. pipe and a hot KZ80 ignition box.

    I started looking for ways to get the most out of the system AND still protect my baby.

    Those iron muffler clamps that hold the engine mount WILL chew right through a 6061 Alum. frame with enough vibration, but billet mounts aren't in the budget...or within my skill set/tool collection to make.
    I decided to armor the contact points were the clamps attach to the frame using sliced up pieces of another one of my bikes that died a noble death and its ghost has been hanging in the rafters haunting me ever since.
    I like to incorporate parts of my old bikes into the new ones... it just seems right to me.

    Out came the saws-all, angle grinder, drills files and all manner of metal shaping tools, out came the trick high tech measuring devices and the aluminum powder flew, parts of the old Trek 4500 hard tail will be on the road again.

    Now please bare in mind these are the first mock ups... be kind.
    I've tried to protect the most vulnerable parts of the frame with adding as little weight as possible...
    with maaaaybe a just little bling.

    My engine kit is some were between Brooklyn and Tampa Fl. as per the UPS tracking system, My trick 48 tooth chaining and heavy duty throttle from S.P.B. are some were over the mid west, and I just got my titanium header wrap from D.E.I. motorcycles... At least i got SOMETHING today...
    Maybe I should start thinking about pipe hangers?
    Im thinking of an "up" mount to keep it out of the way of the dreaded road craters and flying loose asphalt NYC is so famous for.
    Stay tuned
    (sorry about the photobucket link, for some reason it wont let me upload my pics normally, I wish my daughter was
    Last edited: Mar 16, 2011
  6. buzbikebklyn1

    buzbikebklyn1 New Member

    Oh how things change in a year... I ended up selling that engine kit to a customer because I just wasn't ready yet... Please read my latest post.
    Last edited: Mar 16, 2011