92 Zaskar, rebuilt and updated

Austin Dave

Dirt Disciple
I need three more posts before I can post pictures so I'll break this into thirds:

So, a year ago last spring there was an interesting ad on Craigslist, locally. The subject line just read "Mountain bike." The pictures showed it to be a Zaskar. They were asking $90, for the bike. I went and checked it out. It was a 1992, and it was built with XTR m900, parts except for the rear brake--that turned out to be a WTB Togglecam. The seatpost and seat were junk. It was a 19" bike-- just my size.

I told the lady selling it that the bike was worth much more than they were asking, and the lady said, "I want it gone." So, I did her the huge favor of buying it.

The bike had been ridden hard, a long time ago, and then it sat in a garage for long time. No one had ridden it in a while. The tires were like cardboard. The shock was spent, the parts were scratched and dirty, the big chainring needed replacing, and, though the frame had no dents, it did have plenty of scuffs, scratches, and scrapes—“Beauty marks,” we’ll call them.

Anyway, I have a strict bike budget, so it took a long time to get the parts together. My goal was to make it a fun, modern trail bike, with vintage character. I'm tall and weigh about 210, so parts had to be sturdy. I chose a mix of original parts, older, reliable parts, and new, project-bike parts. I kept everything I took off, and it’s all reversible.

The only XTR parts I did not use from the original bike on this build were the M900 rapidfire shifters. I've kept them, though, and will try them out sometime (If I can get them to work--they are a little sticky). I like the old Deore top mounts and found some nice ones cheap for this bike.
 
Like I said, I had (have) a modest monthly bike budget, so I took my time with it, and did lots of price-matching and batch-ordering to save on shipping. That was a fun part of this project, for me. In case that game interests anyone, I include the price I paid for every part and where I bought it in the build list below.
 
Stuff that came on the bike, used in the build:
Frame: 1992 GT Zaskar
Wheels: XTR hubs, Wheelsmith spokes, Araya RM400 Pro rims
Front and Rear Detailers: XTR m900
Front brake: XTR m900 cantilever
Rear brake: WTB Togglecam
Cranks, pedals, small and middle chainring: XTRm900
BB: XTRm900
Cassette: XTR m900 12-28

Cost for all that: $90
 
Other parts I bought:
[prices include shipping, rounding to nearest US dollar]:

Fork: Kona Project 2 [$70, new, Bikeman]
Headset: Cane Creek S3 [$32, new, Pricepoint]
Stem: ’08 Easton E70 100mm/6 degree [$27, new, Jenson]
Bars: Azonic World Force 762 mm (30"), 2" rise [$47, new, Jenson]
Grips: Odi Rogue [$17, new, Bluesky]
Shifters: Shimano Deore top-mount 7/8 speed (Ebay, lightly used, circa 1992) [$32]
Brake Levers: Cannondale Coda 900m (used, these are Dia Compe SS5 mkII levers, relabled for Cannondale--early 90s, Ebay) [$25]
Seatpost: Titec AL 235 XC, nickel-plated (circa 1999,NOS, Ebay) [$22]
Saddle: Charge Spoon (Black leather/Ti rails) [$36, used, Craigslist]
Chain: SRAM PC890 [$29, new, Jenson]
Small parts for Togglecam brake: [$20,Thanks Charlie!]
Large chainring: Vuelta SE Plus 46t [$35, new, Jenson]
Tires: Kenda K-Rad [$34, new, Bike.com]
Polish: NevrDull, Mother's Mag Polish, 0000 steel wool [$16]

Jagwires, tubes and brake pads, a spacer, and cable guide, labor for parts-off strip/clean/rebuild (I cleaned and polished the frame, a local home-based bike mechanic striped the parts off and cleaned them and rebuilt it all) : $157

Total build cost: $689 (So, yep, the rear brake is worth more than I spent on the whole bike.)
 
Here are some before pics, naked frame shots and finished bike pics. (Too many from the nondrive side, I know. Rookie mistake.)

The best aspect of this bike is that it's a "rider." This is not one that begged for fussy restoration. The chainstays were so rough that my polishing rags got caught on them. (And check out the condition of the rare-ish GT skewers at the bottom of the page!)

This is a rough an tumble bike. It's as tough as nails, weighs under 25 lbs (without trying), and is an absolute blast to ride. What more could I want in a bike?
https://picasaweb.google.com/dwesterberg/FinishedZaskar


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It even has GT-branded CNC skewers (these are emblematic of the bike's condition when I got it).

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Thanks, Ivinizer! I polished it for quite a while. It had some very stubborn streaks of oxidation. And I liked polishing it, but I learned you can basically polish these frames forever, and you have to stop sometime. I'd much rather ride than polish.

I HAD planned on getting new decals, but I've grown to like it the way it looks naked. It's also one of those frames that is more or less recognizable just from its materials and configuration. People recognize it and ask me if it's a Zaskar. That's fun.

Your frame is gorgeous, Hoss. It's in much better condition than mine and has some of the early problems sorted: the removable derailleur hanger and the welded cable guides are nice features. Pretty bike. I look forward to seeing it all built up.
 
Austin Dave":1wzku71k said:
It's also one of those frames that is more or less recognizable just from its materials and configuration. People recognize it and ask me if it's a Zaskar. That's fun.

Very true.

Good work on the polishing, and I love the Togglecam!
 
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