From Novice to Creator: Shae's Journey Building Custom Full-Suspension Mountain Bikes
Unleashing Creativity: The Quest for the Ultimate Ride
The Unattainable Ideal: Why Mass-Produced Bikes Fall Short
For many cycling enthusiasts, the concept of a universally "perfect" bike remains elusive. Personal preferences in geometry, suspension, and fit often lead to a desire for customization. Rather than settling for minor adjustments, a truly ideal bike often combines specific characteristics from various models, inspiring riders like Shae to consider a more direct approach to design.
An Audacious Leap: Building a Full-Suspension Bike from Scratch
Shae, armed with an engineering background but no prior frame-building experience, boldly chose to embark on crafting his own full-suspension enduro bike. This decision marked a significant departure from the typical path of starting with simpler hardtail designs, showcasing his confidence and willingness to tackle complex challenges head-on.
The Genesis of 'Fake.Bike.Co': A Humorous Nod to Serious Craftsmanship
Shae humorously describes his venture as a "fake bike company," acknowledging the paradox of building a custom bike without a warranty, for a higher cost than a mass-produced, warrantied alternative. His Instagram handle, fake.bike.co, reflects this playful attitude, drawing attention to his unique approach to frame building, particularly his focus on full-suspension designs.
Engineering Acumen Meets Hands-On Fabrication
Despite his self-deprecating humor, Shae's mechanical engineering expertise provided a solid foundation for his ambitious project. Access to a machine shop and skilled welders after hours allowed him to meticulously develop his designs and refine his welding techniques, transforming theoretical knowledge into tangible creations.
Mastering the Art of Welding: A Steep Learning Curve
Unlike many frame builders who focus on hardtails due to the complexities of suspension kinematics, Shae's engineering background made the suspension design less daunting. His primary challenge lay in mastering welding. By utilizing scrap metal and learning from experienced welders, he gradually honed his craft, eventually achieving the proficiency needed to assemble his first full-suspension frame.
The Inaugural Ride: A Cautious Triumph
Shae vividly recalls the maiden voyage of his first self-built bike. Approaching a local trail network with a mix of excitement and trepidation, he donned full protective gear and meticulously tested the bike's performance, gradually increasing the intensity of his rides. This cautious yet successful first ride affirmed the integrity of his design and construction, and he continues to ride that very bike years later.
"High Horse": A Custom Enduro Bike Inspired by Industry Leaders
Dubbed the "High Horse," Shae's initial creation is a robust 170/160mm (front/rear) dual-link enduro bike crafted from 4130 chromoly steel. Its design draws significant inspiration from the Revel Rail and its highly regarded Canfield Balance Formula (CBF) suspension platform, which impressed Shae with its climbing and descending capabilities.
Tailoring Performance: Personalized Geometry and Kinematics
Shae's unique body proportions—tall with a relatively short inseam—motivated him to customize the High Horse's geometry. He engineered a shorter 400mm seat tube to accommodate his physique while maintaining compatibility with a long dropper post. Furthermore, he designed the suspension kinematics around his specific center of gravity, a luxury afforded by building a bike for himself.
Beyond the "High Horse": Expanding the Custom Fleet
Shae's passion for custom bike building didn't stop with his own enduro machine. He subsequently designed and constructed a full-suspension trail bike for his wife, showcasing his adaptability by incorporating a DW-Link-like suspension platform and integrating advanced manufacturing techniques like 3D printing for the bottom bracket and parts of the rear triangle.
The Evolution to E-Bikes: A New Frontier in Customization
Following the successful construction of bikes for himself and his wife, Shae ventured into building an e-bike. This project featured a substantial 180/170mm (front/rear) travel, a Bosch drive unit, and a four-bar suspension platform. While the four-bar design presented its own set of challenges in manufacturing, Shae's dedication to innovation shone through.
Innovating with 3D Printing: The Next Generation of Custom Builds
Shae's most recent project involves an even greater integration of 3D printing, aiming for a more pedal-efficient, short-travel bike (125mm rear, 140mm fork) with a modified DW-Link suspension. By 3D printing the "bottom bracket cluster" as a single component, he anticipates significant reductions in build time and overall weight, targeting a sub-32lb bicycle. He also plans to precisely tune the anti-squat for consistent pedaling feel, demonstrating his commitment to both performance and custom optimization.