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Surly Long Haul Trucker: Custom Disc Brake Bikepacking Setup – Manual Pedal


Latest image taken – 11/7/2017

After booking Colombia, it didn’t take much thought to decide whether or not I was going to build a new rig for this trip or bring my trucker. After shortly deciding on the trucker being the bike I’d be taking. I had to take a look to see what needed to be changed and swapped with updated parts. My Kokopelli rig was a 10spd drivetrain 32/24, with a 10/36 in the rear that sat on 2.1 tires. It was a solid rig that was capable of handling Kokopelli’s rocks, dirt and sand with no problem. I expected this bike to perform the same in Colombia. You can read more about Kokopelli’s Rig on this link. This bike was fully modified for that trip and retains most of the modifications today.

With my latest concoction, I changed a few things around. I adapted a front disc brake setup. This happened after my original forks brake mount snapped off during a crash in Colombia, that left me with no front brake on descents. Shortly after returning home here in the states, I bought and mounted a disc trucker fork to the long haul trucker frame. After my front brake failed after that crash, I knew instantly disc brakes would have been a far better choice due to the terrain and the load being carried.


Brakes:

I went with the TRP Spyre SLC road disc brake for my bike. TRP crafted a fine piece of aluminum and carbon for this brake. It’s light weight, designed for road and cx but can take on mud and mixed conditions. I think this is a great match for the rider looking for a bit more quality, functionality, ease of use and longevity. I see no issues with this brake on the long haul trucker going forward.

What I like most about it is that it actuates both pads simultaneously. This is different than other systems I’ve seen for mechanical systems. What I mean is, when touring you want your bike to have a solid setup this way you can focus on the riding and being there. Also you want to be able to fix your bike in a barn in any event you have a brake down. A straight cable to the the disc brake and a few turns to mount and adjust the disc brake and set.

Adjustment is a fly with this brake. It will require a hex tool and allen wrench to mount. I have mine mounted up easily to my existing Avid brake lever. The pull is very nice on this brake. I have a Shimano 180mm disc center lock rotor which will provide better stopping power and extended pad life. The Spyre SLC disc brake makes for a nice addition to my setup. It should suit most disc touring frames and comes with additional mounting hardware.

Wheels:

I’ve been wanting to get new wheels built for a while. I had my eyes set on the Mavic A719 rims laced to Shimano XT Disc Hubs with DT spokes. I was also stoked that this was my first official set of wheels I built myself.

Drivetrain:

For me drivetrain was a battle of trail and error. From the stock triple, to a double to now a 1×11 setup. I think after riding in different locations and getting a feel for the terrain you can get a better feel for a setup that works best for me. I now run a 1×11/42. This new setup is a keeper. It’s clean, light, shifts smooth and low maintenance will be required.

 

Frame:
Surly Long Haul Trucker
Fork/Headset:
Surly Long Haul Trucker, 4130 CroMo
Crankset/Bottom Bracket:
Shimano Deore
Pedals:
Shimano XTR M-980 Pedals/ MTB Bear Trap Platform
Drivetrain/Cog/Chainring/Chain:
Shimano XT, Shimano 32t 1x 11/42 Cassette 11spd
RearShifter:
Shimano XT SGS (Long Cage) 11spd
Handlebars/Stem:
Shimano Koyak MTB Crossbar
Saddle/Seatpost:
Thomson Masterpiece, Specialized Toupe
Brakes:
Front – TRP Spyre SLC Disc
Rear – Shimano V-Brake/
Leavers – Avid
Wheels /Hub/Tire:
Mavic A719 32h, Shimano XT Disc Hubs, DT Champion Spokes, WTB Riddler Tire 700×45 front/rear
Accessories:
Ergon GP2 Bar end grips, Outfitted with Revelate Designs bags

Kokopelli Trail & Surly Long Haul Trucker

My Surly Long Haul Trucker reminds me a lot like my old BMX bikes. Swap parts, shave dropouts, smaller chainring sizes & cogs, completely mod the bike. However, still retaining its timeless old school touring/MTB style. So far on the resume this bike hauled me across the U.S. back in (2014), and Virginia Blue Ridge PKWY tour in (2015) where I swapped out the drop bars for a MTB crossbar and XT shifters.

I wanted to push this bike to the limit and see how I can modify it for 5 days riding the popular Kokopelli Trail from Fruita, CO to Moab, UT. The 158mi route consist of of mainly 90% unpaved road, single/ double track, sand, dirt, and tech climbing. One thing I knew I would need right out the gate was bigger tires. My 35c Schwalbe’s soon upgraded to 2.1’s, along with my 44,34,24 triple that went down to a 32,24 double.

After making a short list of items that I needed to convert my bike to a bikepacking machine, I still had to make some serious modifications to fit the tires. Purist Surly owners may cringe after sharing that I shaved my chainstays and fork just to fit the tires. But I was confident enough that this frame would withhold the stress factor I put it through. In and out the shop leading up to our departure, the bike was finally where I wanted it to be.


Mickey grinding down my fork to fit a 2.1 in the front.

Frame:
Surly Long Haul Trucker
Fork/Headset:
Surly Long Haul Trucker, 4130 CroMo
Crankset/Bottom Bracket:
Shimano Deore
Pedals:
Old School MTB Bear Traps
Drivetrain/Cog/Chainring/Chain:
Shimano Deore, Shimano 32/24X10-36 Cassette 10spd
Derailleurs/Shifters:
Shimano XT (front) Shimano XT Long Cage (rear) 10spd
Handlebars/Stem:
Shimano Koyak MTV Crossbar
Saddle/Seatpost:
Thomson Masterpiece, Specialized Toupe
Brakes:
V-Brakes
Front Wheel/Hub/Tire:
Alex Adventurer, 36h rims, Shimano LX T660 36h hubs, WTB 2.1 front
Rear Wheel/Hub/Tire:
Velocity rims on Shimano hub, Specialized Fast Trak 2.0
Accessories:
Outfitted with Revelate Designs bags

Surly Orge Bike Check with Mickey Cheng

If there’s anyone who is down to take off for an adventure it’s this guy right here Mickey Cheng. Mickey’s one of the most versatile riders I know. He has a big background in MTB racing and can crush it on a road bike as well. Last summer we went on a 5-day bikepacking trip together in Virginia’s Blue Ridge Mountains where he rode the Surly Pacer camping, climbing and catching picturesque views. You can read more on that story following this link here.

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Mickey recently built up a Surly Orge and swapped some of the stock parts with his preferred custom components. The Surly Orge is one of those 29er’s that will do it all from commuting, bikepacking, expedition touring, and singletrack. When I took it for a ride I couldn’t help but notice how comfortable and well it handled. It’s siting on 2.1” tires, which in turn make up for it not having suspension. The fork has a very wide clearance and fitting up to a 2.5” tire shouldn’t be a problem. The bike is well made for adventure.

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I’ve learned a thing or two from Mickey on choosing bike components. So I trust his recommendations for parts I use for my rigs. One of the parts he recommends is Paul levers, and when you first ride them you will understand why. They’re lightweight and can be adjusted easily for a 3-2-1-finger pull deal. They also spring back very nicely compared to my avid levers on my Surly Long Haul Trucker. He also talked about the Spyke Mechanical Disc Brake which have dual pistons and stop on the dime. They have a really clean design with a very easy setup compared to single sided mechanical discs.

Enough with the chatter, now, Let’s get to the bike!

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The Ultimate Machine: Surly Long Haul Trucker

I’ve received a lot of emails asking about the gear I used and how my bike held up during my summer U.S. bicycle tour. I initially wanted to do infield reviews while out on the road but only had the opportunity to squeeze in a few videos but nothing in depth. However, since my trip is completed I can nip this in the bud and give you my perspective on the bike and gear I traveled with. This gear review will be broken into two parts, one with the bike and lastly the gear which you will find in a second post. Stay tuned for that as it will be featured in the gear section and blog. Continue Reading →