My Mercer CX Build

[FrequentFaller]

For reasons of early midlife crises and a light dose of work burn-out, I started thinking of an "extended" break from work to clear the head.

 

I settled on 3 months in Europe, cycling the big Cols of the Tour de France, some monuments of the Giro d’Italia, emerging Spring Classics (read: Strada Bianche route) and exploring new countries if time allows. To make the money stretch for that long, there'd be a lot of camping, and some home-cooking to boot. Finally, I’ve decided to be on a holiday and not a pilgrimage or crusade. A joyful heart, sore legs and double-espressos, if you will.

 

The decision on the nature of the trip set some key parameters for equipment: 1) I need a bike. 2) I need to carry stuff with it. 3) I need to love looking at it while I’m doing it, as well as when the trip is over.

 

Since there will be a lot of climbing (and I guess descending too) I realized I need racing geometry. With good brakes. My notes kept returning to “Cyclo-cross Tourer”. It certainly makes for a niche machine, but jury is out on the “beautiful” part.

 

That was until I started hitting Google with intent, and stumbled upon Mr David Mercer, an up and coming local frame builder. His work got featured every so often in local magazines. Seeing his personal tourer online, something stirred inside...

 

http://mudcakedface.com/wp-content/uploads/2016/02/MercerBikes-300x160.jpg

(Photo courtesy of MercerBikes)

 

I delayed the necessary phone call, knowing if the price was right the deal would be done and the option to turn back, well, gone.

 

And so it happened. On an ordinary day, using an ordinary phone, from an ordinary location, something with promises of extravagance and artisanal beauty was born. David named his (approximate) price and deposit requirements. I thought about it for a moment and counted on my ability to breathe under water.

 

It became a bit of a timing deal, I guess. Waiting longer to commit would cause hassles given his order book and my envisioned departure date. In the end, we settled on delivery early April 2016. Again, so far off, it seemed almost unreal.

 

The key specifications were:

• Disc brake ready frame and fork
• 700c/29” wheels
• Ample clearance for cyclocross/MTB tires

The  frame would be built in steel, with a Columbus carbon CX fork.

 

The good thing about the extended timeline was that I had lots of time to research and procure components for the build. I also saw our local currency loose its **** twice, while I was sitting with wish-list orders on various bicycle part supply sites. It was obviously great being able to wait these things out a little...

 

I’ll do the write-up in chronological order, to share the agonizing process of waiting with a bleeding credit card in hand.

 

The frame is covered. Ordered 1st and expected to arrive last. Like it should be. I should name this frame Hitchcock for all its suspense.

 

Here's a sneak view of some of the details..."Artisanal"

 

http://mudcakedface.com/wp-content/uploads/2016/02/Cameleon_LuggedDelight.jpg

(Photo courtesy of MercerBikes)

 

Gearing / braking up next

At the time of the build, hydraulic disc brakes for road bikes was just approved by the UCI for use in the pro peloton. Not that I would race at that level…this year…or ever…but…it meant product options started trickling in from SRAM, Shimano and other players. I knew I wanted disc brakes and from previous experience with a touring tandem, I knew I was looking for a hydraulic setup.

 

Both Shimano and SRAM have just launched fully hydraulic setups, with shifters housing the fluid reservoir driving pistons much as we know from the MTB world. A super-sexy setup no doubt, but also rather pricey. Other options included cable/fluid combinations, which would allow me to decouple the groupset/brake setup options.

 

I kept this in the back of my mind as I filled my trolley online, comparing options on price while reading as much as I could about pros and cons either way. In the end I figured: I actually have to start with the brake set up, since everything else would hang off this backwards. Buy Shimano and I will have to go Shimano road gearing. Ditto SRAM, but at least there I would have the option of mixing road vs. MTB parts.

 

This then went the direction of gearing. I’ll be hauling approx. 35kg of kit up 20km passes at 10% ave. grade. That requires MTB gearing at best I thought. Options, options. 1x10, 1x11? 2x11? 3xwhatever.

It became so confusing, I spent days in the fetal position in a semi-catatonic state. Safe word was “Simplification”.

 

I decided to decouple the braking/shifter/speed dilemma by going for a cable-to-hydraulic option from TRP (they call it Hy/Rd, pronounced "High Road"). This allowed me to make the groupset decision later, while being able to look for good deals on standard equipment.

 

http://mudcakedface.com/wp-content/uploads/2016/02/TRPBoxSet-1024x768.jpg

 

Sold as a single caliper, it ships with a 160mm rotor (6-bolt) and adapters for direct and IS mount.

 

Interestingly, with the TRP setup, the hydraulic fluid is housed in a reservoir on the caliper assembly. This makes for a bulkier brake and requires some consideration to limit heel-strike.Its a hefty little unit, with the reservoir located on the caliper body itself - the shiny plate is the cover:

 

http://mudcakedface.com/wp-content/uploads/2016/02/TRPUpclose-1024x768.jpg

Additionally, TRP and several others recommend running compression-less brake housing to minimize drag and create a more direct braking feel. Some research pointed to Yokozuna brake housing, in the league of Nokon, but more reasonably priced. My credit card cried tears the shape of dollar signs as it gleefully gotten itself whipped and abused. The set arrived with brake and shifter housing, promising an improvement in already-sweet shifting (from the experience of my all-Campy set up on the road bike).

 

Back to shifters/gearing then.

A chance discussion with my local Campy dealer opened up a whole new can of worms…what about using a triple Campy Record crank up front? This can be run with a standard 10 speed Campy shifter set, since the front shifter has enough trim positions to cover all three blades. As luck would have it, I was running a Record 10 speed setup on my road bike. All I needed was a reason to upgrade to 11 speed on that bike…eventually. The plan was thought over and then committed to. I picked up the triple crank for next to nothing, and had a triple front derailleur and long cage rear derailleur thrown in. The latter not top-of-the-line stuff, but certainly adequate for my purposes...

 

http://mudcakedface.com/wp-content/uploads/2016/02/Der-768x1024.jpg

 

Of course, one needs a bottom bracket too...I picked up a matching Record BB in the right size. Unfortunately no pictures since this has been dispatched to my frame builder along with the crank. To check clearances, you see...

 

Voila, gearing was sorted (for now)!

 

While the classic alloy Record crankset is something to behold, the theme of the bike turned into black/cream/gold/copper with very little silver/chrome. After some consideration, I found a local anodizing shop and commissioned a "mirror-black" finish. They refused to anodize the blades, which thus still leaves a bit of silver splash in the wrong place. To be sorted.

(More at http://mudcakedface.com/build-projects/mercer-cx-tourer-build/) 

[FrequentFaller]

Now for something to make your head spin...Wheels...(har-har-har)

The wheel size matter was settled almost off the bat: 26" is out, 700c and 29er have the same bead seat diameter and are thus for all intents and purposes the same. One easy thing out of the way.

 

Next up: Spoke count. As I said, I'll be hauling 35+kgs of kit, mostly on the back wheel. While a 32-hole set up could do on the road, I didn't feel comfortable with this on gravel. I settled on 36+. Additionally, I'd like a double box section setup, preferably with eyelets linking the sections. This helps spread the spoke tension over a bigger surface and (reputedly) limits tearing of the rim where the nipple exists, a weak point under prolonged heavy load.

 

To add a minor complication, I'd be running disc brakes, which basically means the rims won't need sidewall braking surfaces. This could help in two ways: 1) The profile could be different (doesn't need to have the initial flat box section) and 2) the rim could be lighter since the heavy reinforcing required for a braking surface would be redundant.

 

You try match that spec to something that is available: 700c/29er + 36H or more + Disc brake + re-enforced eyelets. That's right, extremely limited choices. Almost everything I looked at went up to a maximum of 32 holes. All profiled rims were 32 holes or less and no eyelets.

 

From some research I stumbled upon the DT Swiss TK540 - a touring rated rim which has garnered much praise from those who use it in anger. Here it is:

http://mudcakedface.com/wp-content/uploads/2016/02/DTS_TK540.jpg

(Source: DT Swiss)

 

Notice the hollow box section and eyelets. Unfortunately, at check out it emerged only a rim-brake version was available. Nothing a good spray job can't fix...

 

Getting to the hub of the matter, several more challenges emerged. Since I'd be running Campy gearing, I'd need to get a set of hubs that could accommodate a Campagnolo cassette. Remember, disc brakes? Remember how discs on road bikes aren't that big a thing yet? Remember how Campagnolo tried once to get into MTB parts (and gave it up as a fad that will never take off)? Punch that **** into Google and see what you find. Oh, add 36 holes into the mix.

 

Bottomline for my build: I'd have to go Shimano/SRAM freewheel body with rear spacing at 135mm. All of a sudden, the options opened up: Chris King, Shimano, Hope, White Industries. I settled on a set of Hopes in wet black, with quick release.

http://mudcakedface.com/wp-content/uploads/2016/02/HopeProEvo2.jpg

(Source: HOPE)

 

Hope, by the way, HAD a Campy freebody some time back, but this has become quite impossible to find locally or online. Again, research to the rescue and by all indications Campy could be made to match Shimano/SRAM cassette spacing, especially in 10 speed guise. Never one to take a chance, I researched this a little and found the answer in JTEK's Shiftmate. This nifty device basically converts the cable pull ratio between the Campy shifter to that required by the Shimano/SRAM cassettes.

http://mudcakedface.com/wp-content/uploads/2016/02/JTekShiftmate.jpg

(Source: JTek)

 

Incidentally, this is likely the most expensive part of the entire build, considering its size. Its also not available through any of the mainstream online suppliers and I had to use some obscure shop with a pretty rudimentary web portal. Of course, despite all other intentions, and having hit the "SEND WITH TRACKING" option, it still got to checkout without this and without me noticing...which obviously meant the little sucker hit South African shores with no past and no future. It is likely still stuck in customs  waiting to be claimed. I ended up ordering a second one, clicking "WITH MF TRACKING" ten times to be sure. Still ended up in checkout WITHOUT this checked (WTAF??) which required a mail to the shop to get sorted out. Good thing I had time and our currency got its stuff together just a little bit.

 

@JTEK: You could sell bucket loads of this if you get in with the main bike part sites. Stop being humble about how nifty this is.

 

Anyway, back to the wheels...here's Jean my local builder man busy with the build:

 

http://mudcakedface.com/wp-content/uploads/2016/04/WheelBuild-768x1024.jpg

 

..and the finished product:

 

http://mudcakedface.com/wp-content/uploads/2016/02/RearWheel-768x1024.jpg

 

The sound of the freewheel is something to brace yourself for...the sound of mechanical robustness I think. A bit of a close up of the hub.

 

http://mudcakedface.com/wp-content/uploads/2016/02/RearWheelCloseup-768x1024.jpg

 

You'd have noticed the Schwalbe Marathon tire already mounted. This wasn't my initial first choice, but after speaking to a couple of long distance expedition riders, their feedback was more or less unanimous: The single most-valued piece of kit they have used on their tours turns out to be this particular tire. No mean feat, actually, beating "double-ply toilet paper in Nairobi" (I kid you not) by some margin...

 

All this robustness makes for a pretty heavy setup: I don't even WANT to weight it. Bargain on 3.5kg+ for the wheelset with tires.

 

You might recall I mentioned running mechanical discs on a touring tandem some time back? On two occasions I managed to glaze the pads so comprehensively that they had no braking effect at all. I realized afterwards (likely while cleaning my underwear) that the correct braking technique on a long descent is to let the rig run and apply hands full of brake to take off speed as you approach corners (vs. dragging front/rear the entire time). This stops the system for overheating, which causes the brakes to go all spongy, and the pads to glaze over. Of course, it takes some courage to try this for the 1st time...

 

In line with this lesson, I decided to go with the supplied TRP 160mm rotor at the back, but up front to rather run a 183mm Hope unit. The latter will obviously require a spacer, but this is easily sourced from my local bike shop.

 

More at http://mudcakedface.com/build-projects/mercer-cx-tourer-build/

[FrequentFaller]

While waiting for the frame to be built, I started looking at saddles and other finishing kit. While there are several options to go for, in my mind there was only one final choice: Brooks. I bought their Swallow for my roadbike and was so impressed by the packaging (I know, ALL the reason to buy a product), that I promptly followed suit with an order for the Swift, a slightly more touring-orientated version.

 

Nothing can quite prepare you for the sense of awe when you receive a vintage-printed box with a heft to it that speaks of a form-and-function-over-weight mindset. As the box slid open and the saddle was revealed bit by bit, I held my breath...this thing is beautiful!

 

http://mudcakedface.com/wp-content/uploads/2016/04/Brooks-Saddle-768x1024.jpg

 

I ordered a set of matching brown leather bartape, perforated for an old-school feel.

[eddy]

Nice. Keep us posted

[amasendeinja]

Awesome thread.

[BenReaper]

Sounds like this is going to come together nicely.Looking forward to the conclusion and the finished product.

[Frosty]

Very cool write-up.

I will be following with great interest.

 

I have contacted David twice (in the last 2 weeks) for a custom build.

The current queue extends to January 2017, and only firm once a deposit is made.

[FrequentFaller]

I hear you re. the lead time. In a way I'm glad I pulled the trigger when I did, "only" had to wait 6 months...and the fact that this is extending vindicates it.

 

Realistically though, where else can you buy custom for a reasonable price and wait less than a year? I suspect his order book will start getting filled with overseas orders very soon (if not already).

[Xanthe]

Very good read!

 

Love the saddle!

Edited April 4, 2016 by Xanthe

[ichnusa]

I love these kinda threads - the passion is palpable - look forward to the rest!

[Cyklon]

Have to agree good thread

[rouxtjie]

While waiting for the frame to be built, I started looking at saddles and other finishing kit. While there are several options to go for, in my mind there was only one final choice: Brooks. I bought their Swallow for my roadbike and was so impressed by the packaging (I know, ALL the reason to buy a product), that I promptly followed suit with an order for the Swift, a slightly more touring-orientated version.

 

Nothing can quite prepare you for the sense of awe when you receive a vintage-printed box with a heft to it that speaks of a form-and-function-over-weight mindset. As the box slid open and the saddle was revealed bit by bit, I held my breath...this thing is beautiful!

 

http://mudcakedface.com/wp-content/uploads/2016/04/Brooks-Saddle-768x1024.jpg

 

I ordered a set of matching brown leather bartape, perforated for an old-school feel.

I have the exact same saddle on my SS...its a thing of beauty...but here is the really good news.

 

It becomes like an old pair of vellies after 4-5 months....its molded to your behind and no one elses so it becomes like an extension after a while...Kind of like penguins that pair for life...this saddle pairs with you

[eddy]

 

 

Kind of like penguins that pair for life...this saddle pairs with you

 

I get nervous when I see the point on that thing.

 

Buk jy of mik jy ?

[gummibear]

Nice story

[rouxtjie]

I get nervous when I see the point on that thing.

 

Buk jy of mik jy ?

lol now that you put it like that...not the best example

[Beattbox]

Fantastic thread! Well done.   Can't wait for the next installment.