R and D

Research & Development Focus

The research and development tradition that Cleland draws upon goes back for over 30 years of continuous innovation and field-testing. We are currently testing a range of components and technologies in order to ensure that, if ever there is a production run, these bikes are as capable, reliable and efficient as possible.

On this page we’ll be posting news of what’s being tested, designed, considered, conceived in the hope that you’ll be interested, entertained and possibly amused. Additionally, we trust you will give us your views, opinions and comments.

It’s always worth a quick look at the latest pictures posted on the associated Flickr photostream for interesting stuff about hardware tinkering.

A test (of sorts)

The last two weeks of October were spent in Devonshire. Lovely ancient sunken lanes, high banks either side overhung with trees, usually very muddy and sometimes a rocky stream beneath the tyres.

Such is my confidence in the current AventuraTT prototype that I didn’t take any tools or lubes with me, not even a pump.

I rode nearly every day, riding familiar routes as well as seeking out some paths I haven’t tried before, and in quite a few cases, it seems quite possible that no-one has ever tried before. The first few days I was surprised how dry the old ways were, then came one month’s rainfall in 24 hours! I didn’t ride that day.

The AventuraTT was left out-of-doors and not covered over for the whole two weeks, when not being ridden.

It performed impeccably, no mechanicals, no punctures, no maintenance, no worries. It’s wonderful, after so many years of machines that had to be constantly adjusted, inevitable breakdowns and punctures, rust and water contamination. Now I can just ride the thing and not waste my time cleaning it and checking for damage.

A bit late for me, I wish this bike had been around when I was in my twenties.

If you’re looking for fast and light, you won’t find it here; nothing wrong with light and fast, it’s just that the Cleland philosophy is for reliable, trouble-free riding. The result of so much R & D, and for these qualities, there is an inevitable weight penalty. The best way to ride the AventuraTT is more like taking a relaxed walk, looking around and enjoying your environment, taking on the occasional challenge and whizzing downhill. Most mountain-bikers I see seem to  ride as if they have a very urgent appointment to get to.

New frame design

As often happens with projects of this kind; things change...

So, just to whet your appetite, here is a sneak preview of  a possible production model. The frame design resolves all the issues of clearance behind the bottom bracket and improves the step-over ~ rather important on a high-rider like this. It has a tall headstock to support the handlebar and more support to the seat tube as well. A new prototype will have to be built and supply of a small number of frames organised. If it all works out, production of  batches of  five or ten units will become possible. Unfortunately, building bikes in such small numbers will mean all the components that are not hand-made, will cost not much less than if you bought them in your local bike store. Do the sums yourself…

The rear wheel drop-out will still be similar to the TT prototype: laser-cut stainless steel which, because it is relatively easy to produce a variety of drop-out designs in smallish quantities, means there can be several drop-out configurations. For example, variations can include:

• disc-brake mounts
• various pannier rack mounts
• brake anchor-arm mount
• pivot point/mount for the chain tensioner
• configurations for  31″, 29″, 28″ or 26″ wheels
• configurations for higher or lower hanger-height (affecting steering angle)

The permutations are considerable! Of course, some drop-out plates could incorporate several options in one. Also, with this system it is possible to remove the rear wheel by undoing the drop-out mounting bolts with an Allen key, leaving the drop-outs in position on the axle; is this is a good idea?

Now I’m wondering if a similar form of variable drop-out system were incorporated into a front fork design, you’d get the universal bicycle! Anyway, for the time being, a stock front fork is going to be used.

Additionally, it may be possible to make a bolt-on variable bottom bracket assembly… Whoa!! You’re getting ahead of yourself here!

Update:

Nice idea, and the manufacturers seemed interested. Unfortunately, this scheme is probably a non-starter.

AxisBarClamp

Here’s something I’ve designed which I’m sure should be on the market already; a handlebar clamp that fits on top of the steerer tube and puts the handlebar above it, instead of forward so you can steer directly through the fork axis. Also, because of the raised position of the AventuraTT, it will save a lot of handlebar metal to get up there. I’ve searched and searched, but cannot find anything suitable.

So, out come the pencils and eraser… This clamp design combines the top cap into the clamp assembly; you fit the lower part first and adjust the headset, then you fit the handlebar in place with the upper clamp. I’m contemplating incorporating a lamp bracket as well.

AxisBarClamp update:

I’ve finally got the new handlebar clamp sorted out and a new arrangement for the cockpit generally; much tidier and less metal involved.

 

Jox re-design

Having become somewhat pissed off with shelling out £10 or so on some sealed bearing jockey wheels, only for them to be completely worn out in about a month, I decided I’d design and make my own.  First thing I wanted was bigger bearings; the usual size is about 15mm diameter. I did a bit of research and found I could make a 13 tooth jockey wheel with 42mm bearings. I made these with open bearings and with a chain guide flange, which doubled as bearing shields. These flanges also had grease ports so the bearings could be fully re-lubed without removal from the bike. They have worked extremely well for the past year, and still show no signs of undue wear. However, the new design is prompted by two factors:

• Through the summer I’ve been using dry chain lube. Grease, oozing out from between the flanges, was also greasing the chain, not a bad thing, but not really very desirable with dry lube.
• The chain guide flanges meant that bits of vegetation and muck were all gathered in by the chain and compacted around the jockey wheel, making for a surprisingly lumpy transmission. It didn’t appear to affect efficiency, but it felt very odd through the pedals. (February update: I discover this is much less of a problem in winter, therefore most of this is caused by vegetation.) I am also not happy that grime could be forced into the bearing by this route, although re-greasing would force it out again.

So, redesign time. 

With the use of Chain Choobz, these act as a chain guide, so I no longer need the guide flanges. I’ve increased the number of teeth to 15, and chamfered the teeth more like a conventional jockey wheel. The toothed part overlaps the shields so contamination is less likely. The hybrid ceramic bearings are rubber sealed, PTFE cage and stainless steel body. And the red bit you can see if you click on the image is special grease used as a dynamic seal. These are now in process of being made by Harry Haworth, the magic machinist. 

Update

The new Jox are made. Now they have to be finished with a bit of polishing of the teeth, and the central bearing mounts will be sprayed Red.

Update

Having fitted the Chainchoobz before fitting the new Jox, and summer vegetation in now full growth (June 2011), it would appear an unexpected benefit is that the tubes stop grass and stuff getting in between the guides. Since I’m working on a new design of chain tensioner, I’m postponing fitting the new Jox until it’s ready to fit.

New Haworth swing pedal design

The Haworth ‘swing pedals’ have been redesigned to incorporate larger bearings. These prototypes will be fitted with ceramic/stainless steel/ptfe bearings (at £40 a throw!) which are also rubber-sealed. However, rubber seals alone are not enough in Cleland, where bearings, even rubber-sealed ones, get lubed with mud. These pedals will also have bearing shields covering the seals and when fitted, have some very thick synthetic ’Losi’ grease as an additional dynamic seal. The bearings are set closer to the crank to minimise Q factor.

The platform is slightly lower and bigger, with support struts across the middle. Here are the prototypes being made. You can see how primitive the methods are, no CAD millers and lathes here! We don’t have that kind of money.

You can see a photo of the finished pedals here

NuVinci test hub

We’re very excited to learn that Fallbrook Technologies are going to supply a test NuVinci hub gear. Briefly, this hub has an infinitely variable gear (within its 360% range, of course) and sounds perfect for the job. The internal workings are completely sealed, due to the technology, which relies on a special liquid. The freewheel drive and selector are not sealed, but are fully serviceable, so come the new year, we’ll see if it’s up to the mark.

Also in the new year, as well as the new swing pedals, we’ll see the fitting of 31″ wheels. Additionally, a new handlebar design (not very different to the existing one) with a lower cross brace, the present one gets rather close to my nose when I’m ducking under low branches.

Thornguards

Up here in the Scottish Borders, the population is so low that the trails become readily overgrown, and many are less wide than the handlebars. Fed up with ending each ride with scratched and tingling fingers, particularly the third and little fingers, from encroaching thorn bushes, and during the summer, 5ft tall stingers, I’ve designed and fitted these handlebar thornguards.

 

 Thornguards update:

Did they work? Well, yes and no. They need to be bigger all round. As they are in the picture above, briars hanging down from overhanging trees got between the brake lever and guard, ripping my pinky and eventually ripping the guards right off. It turns out that thorns are less of a problem than briars, so ‘thornguards’ is not an entirely appropriate name; I think ‘Finger Fenders’ would be better. So, back to the drawing board…

Finger fenders

…and this is what the new ones look like. They seem to look a bit big to me, but maybe I’ll get used to that. They are very flexible, being made from mudguard material, and they may need to be extended top and bottom.

Another update: (July 29 2011) Yep, I’m quite used to their size now, and it’s great to plough through stingers or brambles without getting stung or scratched. That doesn’t apply to my legs, though. Hmmm, thinking cap on.

Current areas of research also include:

• Suitable tyre and inner-tube combinations that are able to function at pressures of 7-15 PSI, whilst maintaining reasonable rolling resistance characteristics. This knowledge is needed to ensure the excellent traction, comfort and soft terrain characteristics that made the old Clelands so special, but so heavy! We want to see if there are any present-day options available which will save weight.
• Parallelogram type suspension seat-posts vs telescopic type: what are your experiences and views?
• Chain-guards and chain-cases. We are developing a plastic tube style chain guard and comparing it with the more conventional style as on the AventuraTT. There are photos of the latest developments in the Flickr photostream.

Above all we need to understand the variety of uses to which the Clelands may be put. Although the Aventura is primarily designed for off-road use, it can form the basis of a good all-rounder commuting bike, due to the excellent control and superb visibility afforded by the high riding position. Or it could make a good ‘Country Bike’ due to its weather protection and low-maintenance ethos; or a comfortable and exceptionally reliable long distance tourer, particularly for those who like to sit up and watch the world go by.

One thing is for sure; the new Cleland will be distinctive and fresh in a world where off-road bikes look increasingly complex and astonishingly alike.

If you have any particular interest in the area of research and development, or a have burning question to ask, use the reply box below to keep the information flowing…

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