Complete rebuild of 1990's MTB to 2016 XT spec 1x10

[NewRider]

Next came fitting the derailleur and its initial set up involving setting up both stop / travel limit screws and setting the B screw to roughly the correct position. These three tasks were easily achieved with plenty of tolerance still present for future adjustments if required.

Then I measured and cut back the gear outer housing allowing for the in line adjuster that I want to fit. I feel that this in line adjuster will present great advantages at the back of the bike when it comes to fine tuning especially as mine is not a standard set up.

I also fitted my new stainless bolt fitting in place of the one that came with the original aftermarket traditional hanger. This mushroom head bolt has a hex head fastener and I have cut it down to length to match the other so the fit is nice and tight without extending out of the back of the dropout.


Some photos below...

 

[KermitGKona88]

Re:

I just can't reconcile that you are spending so much on the drive train and so little on decent brakes :facepalm:

 

[NewRider]

I then finished installed the Shimano XTR inner cable and the outer housing and connected this to the derailleur. After work I then tried the shifter and the gear selection was working well until it reached about halfway up the cassette and it was starting to just starting to become noticeable the adjustment was slightly out. After running it back up the gears I readjusted the cable and fitted the KMC X10.93 chain.

An hour later and the chain was moving down the cassette really well but again was not making it past the third from lowest cog. In addition to this while I adjusted the tension on the in line adjuster to be perfect at the high gear it would be wrong half way through the cassette. If I then changed the tension at that point it would carry on down into the second largest cog but no further and then would start go out of adjustment when coming back into the high gears. After a little head scratching it was then Phil and myself realised the problem. I had positioned the in line adjuster to sit straight into the rear derailleur mount and in the small / high gears there is little tension but as you pull the derailleur around the in line was being pulled into the derailleur mount and then as the tension released it would move back out.

As a result I will be rebuilding this area of the cable to put 40mm or so of outer cable to sit sit in the derailleur and the in line adjuster and this should solve this. A bit of a school boy error, but I am learning about bikes for the first time so not being to hard on myself.

 

[NewRider]

An update...

Yesterday together with Phil we popped into work as everything closed to complete some final tweaks on the bike and adjust the seat height and everything to suit me. Set up the front and rear brakes, and adjusted the cable line on the rear derailleur in line adjuster. This time setting up the derailleur has been a breeze and I can now go through the whole range of gears fine, however the only issue I have is that when the clutch is set to ON i can not reach my bottom 42t cog. After looking at it this is I believe because the derailleur is rotating too far forward and going outside of the operating range of the clutch. I can slacken of the clutch but that would make it pointless so I went to my local bike store and purchased a second KMC X10.93 chain.

With the chain undone and a length of wire threaded through it to hold it together Iso the derailleur is vertical in the 42t cog I have gauged I need to add two links in to the original complete chain.

Some photos below...

 

[NewRider]

More photos...

 

[NewRider]

Having added the extra two links the derailleur is now moving up onto the 42t no problem at all with the clutch on and the gears are all working as planned. The chain is dropping off the 42t if you back pedal but this is due to the extreme line of the chain from the chain wheel to the 42t.

Phil has taken the bike for a ride around and states everything is working brilliantly and the back peddling shouldn't be a issue as there is no need to be doing it in such a slow gear. The brakes he states are more powerful than he had expected them to be but obviously nothing like the discs he is now used too.

Some photos below of the finished bike.... All down to me to getting riding and get my confidence up and the miles ready ready for the big wheelie charity event. I think my dad is going to be quite shocked as to what his old Apollo has become...

Thanks to everyone for the support and I will post some better quality images of the bike soon, together with the weight differences between the original parts and the new together with costings for the project.

Should anyone be interested buying a hanger let me know as my friend Phil is determined there is a market for this but I suppose its all price dependent I know.

 

[NewRider]

More photos..

 

[redzephyr]

Re:

Congrats NewRider, the bike looks great - nice choice on the seat too.

It's a fantastic first build thread, what you did in a month was superb.

 

[k-rod]

Re:

dude - awesome build, awesome thread ... and excellent work!!

Congrats.

 

[kingbling]

Now THAT gentlemen is a build thread

Newrider you have done exceptionally well in the build and in the thread, all it needs now is a picture of you riding it and your dads jaw on the floor when he sees it Brilliant