Perhaps no builder epitomizes the intense, eccentric inventiveness of mountain biking’s inception like Charlie Cunningham. And we now have a superb glimpse of his unique contributions by the like-named but unrelated, Richard Cunningham of Pinkbike. Both, by the way, living examples of eyes-wide, bold cleverness in the pursuit of 2-wheeled dirt. Please check it!

In his April 11 post, Richard explores Charlie’s 1978 CCproto that includes so many years ahead ideas, he could barely fit them into 1,500 words. None of us who’ve shared this era can deny Charlie’s many influences on each of our work, a true Hall of Famer.

Sloping top tube, 1X gearing, oversized rear cogs, extra wide rear hub, dropped bars,… 40yrs ahead of its time. © Cunningham bicycles

To many in the day, Marin seemed a fantasy land—tinkering with dirt cycling, consciousness, rampaging around various watersheds, light shows at house parties, a bit unhinged. The joy of taking cycling down a somewhat different path was too much fun. For kids, like visiting a chocolate factory.

Chocolate, that mesoamerican delight, nearly addictive for many, health enhancing (in moderation), never out of season; seems an apt metaphor for the playful indulgence of mountain biking’s early years.

For his part, writer and inventor, Richard Cunningham packs a career of surprises and discoveries. Wish I had an image of him on his horse, but here’s another typical scene.

WWI Fokker Eindecker-inspired airplane, a machine hand-built by Richard.

Thought I saw RC the other day. Nah, maybe Eddie Vedder.

Sadly, Charlie’s inventive career was interrupted several years ago when a bad crash left him with brain injuries. Now, with the care of his wife, legendary racer and writer Jacquie Phelan, and many friends, Charlie works hard every day to recover and enjoy what he can. He needs your help. Consider contributing to Charlie’s recovery fund.

While mentioning Jacquie, let’s remember one of her more famous fashion statements from the era—a mud covered RockShox moment. Funny how much that mud looks like chocolate!

Maybe it was chocolate?

Trick procedures are as important to your tool box as the individual tools. Please share them whenever possible. In that spirit, check these:

Proper dial indicator use

Plunger dial indicator

Indicators magnify movement and provide numbers to better judge trueness. However, your standard dial probe indicator is not made for rapidly moving surfaces. Even when an indicator is fitted with a bearing, the measure surface (rim brake track or edge) should only move slowly for two reasons:
1/ The probe is not designed for sideways force. Its accuracy is wrecked if the probe bushing wears.
2/ The probe return spring is as weak as possible. Consequently the probe can jump off the test surface with a tiny bump and vibrate with a pattern of roughness. To navigate a rapidly moving surface, the probe would need a strong spring and a dampening mechanism to maintain contact.

Spinning a wheel on a truing stand is normal when a light gap is used to watch trueness. A gently spun wheel can turn at 60 rpm. With a full sized wheel, this is 4800”/min, the same as a 1/4” drill at 6,000 rpm. This is not slow speed!

So, move your wheel at any speed for visual truing but turn it slowly with dial indicators. Don’t let your measuring instrument use cause machinists to cringe!

Bearing play
Builders deal directly with hub bearing play. Play interferes with truing, even when it’s too little to bother riders. In some hubs, play can be adjusted to zero for the build and then returned to the recommended amount for use. In most cases, however, it must be tolerated.

How to measure play? Axle play is magnified 10X at the rim but quantifying is delicate work. Hold the rim where a dial indicator is located. Give it a slight lateral force, left then right. The wheel is easy to flex so your finger force must be extremely light to reveal bearing play only.

What is reasonable? No single answer exists for all wheels. One number many experts would approve is 0.008” (0.2mm) at the rim (TIR—total indicated runout). Such a reading at the rim can be produced by less than 0.001” (0.02mm) movement at the axle. These numbers are at the very extreme of manufacturing tolerances for consumer products. More accuracy may be needed by NASA, but not us.

Heat Guns rock

Trusty heat gun

A must around any shop is your standard 1500W heat gun. Like anything with voltage and heat, special care is important—flammables must be far away and good ventilation present. Some of my favorite uses:
1/ Removing adhesive vinyl stickers from nearly anything. Vinyl stickers lift off effortlessly with the right heat. Use less until you discover the perfect amount. Be careful not to damage your surface.
2/ Heating metal so stuck screws or bearings can be removed. Heat makes metal expand, each material with its own CTE (coefficient of thermal expansion). Aluminum expands much faster than steel. But even in steel-to-steel assemblies, a larger unit will expand faster than a smaller (like a stuck screw). Frozen nipples are a good example.
3/ Drying touchup paint, adhesives, spoke prep, rinsed chains, etc.
4/ Removing old sewup glue from metal rims. Heat then scrape or wipe with steel wool.
5/ Lubing old leather saddles. Apply a preservative cream or wax, heat the area and watch the saddle inhale the lube. Be sparing, it’s easy to make a crispy old saddle way too oily.
6/ Paint removal where the substrate can take the heat. This works on metal or wood. Paint softens before burning and can be scraped or wiped off.
7/ Applying shrink wrap. Handy shrink wrap is available is many colors and diameters, used extensively in electronics. Find ways to employ it on bikes—bar tape or cable end finishing, for example.

Got some other tricks? Wheel specific? Please share!

In 2011 I enjoyed building two wheels with vintage Prior hubs and wood rims. They were destined for a 1930’s Australian Speedwell track bike undergoing restoration by Bobby Landry in Colorado. This week I saw the finished product and it’s worth the wait! Read more →

Wheel building is booming, though it’s rare to see evidence in the cycling press. I’d call it a work in progress, rather like craft brewing back in the day. Pioneers were scrappy and uncertain. When they first appeared, the big brewers knew it would be sporadic and limited (college towns, resorts). They actually got murdered over several decades and now craft brewing carries a large percentage of that market. This seems to be happening with wheel building. 

Today most small builders are in likely cities (Portland, SF, Seattle, Boulder, LA…) but their global rise (UK, AU, NZ, EU…) shows it’s not a local trend. Your area may be barren but many successful builders are elsewhere. Check these, among hundreds more:

• Magnetic Wheel Co. (Portland)
• Monument Wheel Works (Seattle)
• Diablo Wheel Works (Pacific Palisades, CA)
• Ergott Wheels (Islip, NY)
• Joe Young Wheels (Granbury, TX)
• Noble Wheels (London)
• Wheel Tec (Alkmaar, NL)
• Melody Wheels (O’Connor, AU)

Not personal recommendations (but all excellent). The more you look, the more you’ll find.

If you are contemplating getting underway I recommend exploring two questions.

Where Am I?
You may plan a strong web presence but your immediate scene is your most important asset. Local riding is a key element in your opportunity.

© Sugar Wheelworks (Portland)

Put aside personal preferences and experience because, as a wheel builder, you should welcome, understand, and whisper to all forms of wheels. Can’t do too much research and preparation to cultivate your local community.

Who Am I?
There are many types of builders. Wheel construction seems pretty straightforward but those who succeed do not share one approach. One science I hope, but not one style. Who are you? Understanding your style helps direct your effort and avoid confusion.

1. Hobbyest
Handy with tools, good with gear, likes self sufficiency, finds building fairly easy, builds own and wheels for friends and family. Not so keen to make a simple task complicated or dramatic.

2. Social
If you’re gregarious, wheel building can bring quite a range of human variety your way. Creating a business around the needs and exploits of riders is attractive to customers. You’ll want a welcoming workshop with plenty of ambiance and regular outreach.

© gravy wheels (Novato)

3. Nerd
Many an engineer type is drawn to building and customers, in turn, to them. Emphasizing tech with gauges and instruments, sharing spreadsheets and charts, teaching the “how” behind wheels can be a central theme if that is your drift. But it is not necessary to reek of tech. Performance minded customers need to trust but rarely require knowing all about the science.

© Cutlass Wheels (Baltimore)

4. Artistic
Wheels are beautiful and there is room for plenty of self expression for a builder. The bar is very high for visual compatibility with the bike, high finish of components, and unity of design. Aesthetics are an ever changing scene, rules flex, styles evolve, and builders help drive change. We’ve all noticed what fixies combine on machines so basic they simply showcase wheels.

© Roues d’Olive (Fully, Switzerland)

We are combinations of such types but discovering that inner builder is key to separating your offering from vague and mainstream options. Riders seek custom building for more than alleged benefits of value or performance. They want to deal with a real person, not just an “add to cart” button. There is no “better” style but the clearer yours, the greater authenticity you broadcast.

Authenticity attaches to wheels, gives them karmic power riders remember for years. Authenticity of our prized possessions adds meaning to our lives. That’s your ultimate product as a custom wheel builder.

Go for it and please share your experiences with others (and me :-)!

Little minions to keep you company.

A new product and the return of an old favorite, what good news for the coming season!

We’ve added Pedro’s new spoke wrench. Three sizes, a delightful and original design, likely to become many builders’ go-to wrench. Pedro’s stuff is always a pleasure. Uber sturdy construction, no shortcuts, and trademark screaming yellow…what’s not to love.

Three sizes cover the range for 14 and 15G nipples: 3.23, 3.30, 3.45mm. Each tool features a reversible hardened steel insert offering a fast on and off, straight side opening and a 4-side drive, diamond shape.

Diamond jaw on top, straight side on bottom.

Best news ever is the return of our nipple shuffler trays. While most efficient nipple lubing uses a strainer, pre-oiled nipples tend to drip. When you sprinkle them into your shuffler to begin lacing, a catch tray would be handy. We ran out last year and it’s been many months without.

Routed from a hardwood remanent block.

Your shuffler sits up on the corner shelves. The wood loves oil, so everyone is happy. Just received 50 from Jon, a variety of woods, all magnificent. You’re welcome to make a request in the “notes” area at checkout but I’ll not be listing or selling them by species.

50 trays.

Junzo Kawai died this week at age 94. Some details were published in Bicycle Retailer.

Mike Sinyard, of Specialized, says gracious things in the BR&IN article. The effect Mr Kawai had on the world bicycle scene can hardly be overstated. Today, those he mentored, supported, supplied, and encouraged are deep in thought. It’s not my place to dignify such a career or “set the record straight” but a few words feel worthwhile.

Junzo Kawai, chairman and driving force behind Maeda Industries (Suntour) in the ’80’s and ’90’s. © SunXCD

Many of us captivated with cycling in the mid 1970’s, in the US and particularly on the West Coast, ignored the prevailing wisdom, “to get into plastics,” etc. Instead, we headed out on the roads and trails and tried to master an old and special sport. Some of us were clever in our minds; so inventive, so resourceful, so gifted to challenge convention and reinvent many of the basics of cycling.

However, the players of those early years in the US had little support. Europeans were great hosts and freely shared their enthusiasm. But finding resources to make change, to build companies took buy-in from beyond. That included members of a generation of Japanese war survivors who listened and collaborated with Americans who were, essentially, children of their recent adversaries. How did Mr Kawai and his peers find the wherewithal to give so much?

Talk about reconciliation, together we built something that was bigger and will outlast all of us. All due credit to US initiative, sacrifice, and ingenuity. But you won’t find anyone from that period, and that includes the entire pantheon of industry names (and more), who disputes that the steady support of people like Mr Kawai made the difference. I hope a stream of testimonials flows over the next few months as we acknowledge this crucial part of our industry history.

Mr Kawai (gray suit) at the helm of one of cycling’s all time most influential and dynamic companies. © SunXCD

The important point is to be grateful to those (he wasn’t alone) who helped restart our industry, an effort whose effect has not diminished nearly a half century later. More important is to hope we will, in time, be regarded with similar gratitude. It’s everyone’s choice.: to solo or to mentor. To hoard or to share.

As our planet evolves at hyper-speed, hurtling towards an uncertain future, let Mr Kawai’s example help us rise to the challenge. It is a privilege to share mankind’s cleverest device and a duty to reply to the future with the integrity and passion of Junzo Kawai.

Last year he founded a company, SunXCD, with members of his family.  Check it. He says “the market is too race-centric;  carbon fiber, electric shifting, full suspension, 11 speed, doesn’t really enhance the enjoyment of cycling. In the 1970’s and 80’s we cycled to be closer to nature, for the environment, for our health, for the simple beauty of cycling.”

Condolences to the Kawai family. Best wishes to his son-in-law, Taki Takimoto, who heads Sun XCD. And good luck to all of us, appreciating the meaning of Mr Kawai’s life and work.