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putting together a custom cassette.(11 posts)

putting together a custom cassette.rufus
Sep 3, 2003 3:03 PM
i want to take a 9 speed ultegra 12-27 cassette, and make it into a 13-27, with a 16 tooth cog in the middle. i really don't need a 12t, but i do need lower climbing gears. i can do this two ways:

i can buy a 13t first position cog and a 16t from harris cyclery for about $20. or i can buy a complete 13-25 105 cassette for about ten bucks more, and use the 13t cog from that, and separate the 16t cog from the cluster. then i can build a 13-14-15-16-17-19-21-24-27 cassette, and also have a 12-13-14-15-17-19-21-23-25 as a spare.

105 cassettes don't have the larger cogs bundled together on carriers like ultegra and dura ace, but held together by some type of pin or rivet. my question is, are these held together by screws or pins that are easily undone, or will i have to drill or grind the heads off rivets to separate them?
I've disassembloed both styles.Spoke Wrench
Sep 3, 2003 4:30 PM
Either way it's not much work. It's been a while but I think that the last time that I disassembled a riveted cassette I used a bench grinder to grind the heads off of the rivets.
what did you do with the ones on carriers?rufus
Sep 3, 2003 6:44 PM
can you pop them back together on the carrier or something? cause unless they are on a carrier, which has the grooves for the freehub body, they aren't much use.

yeah, i assumed i could just grind the heads off, or if they didn't stick up much, drill them out until i could pull the cogs off.

my 7 speed cassette had screw-like posts with big heads that you could unscrew with pliers, and i saw a sram cassette today that had two solid pins, and then a third that looked like it could be unscrewed with a tiny allen key. but i believe new shimano cassettes are riveted, not screwed together.
what did you do with the ones on carriers?Al1943
Sep 3, 2003 6:52 PM
It depends on the cluster. On the Ultegra cassettes it looks as if the mid size clusters with 2 cogs are usable when disassembled. The larger clusters with 3 cogs are not (at least from what I've seen, I just looked at a 12-25).
Sep 3, 2003 6:45 PM
Buy the 13 and 16 and 13-25 cassette, then you'll have a 13-27 and 13-25, both with 16's and you won't have to grind or drill. And you'll have a spare 12 if you ever need it.
well, now we're getting into money. ;) nmrufus
Sep 3, 2003 6:48 PM
Not really.Al1943
Sep 3, 2003 7:00 PM
Cassettes don't last for ever. If you have two, use two. Change them out or put them on two wheel sets and alternate wheels. There's nothing expensive about Ultegra cassettes compared to other bike parts. If you wear them out you'll definitely get your money's worth.
Sep 4, 2003 2:17 AM
I was mulling over this very same thought this morning, dont know the answer though !
re: putting together a custom cassette.LC
Sep 4, 2003 9:28 AM
The 16 and lower cogs are loose on Ultegra and Dura Ace, so you don't have to get 105.
Not according to the charts.Chen2
Sep 4, 2003 10:25 AM
The Shimano charts show that all of the current 9-speed D-A and Ultegra 16t cogs are combined with 17t cogs. The European web site has charts and exploded views of the cassettes. But I think the rivets can be removed and the cogs used separately, haven't done it myself though.
yes, as al said.rufus
Sep 4, 2003 10:59 AM
you can separate the 16-17, and still use them on a freehub. trouble is, according to the prices in the quality bicycle parts catalog, a 16-17 carrier costs about what you can get an entire cassette for.