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im - 11/19/2006 09:32:00 PM

Occasionally, we get questions about how to haul a Pugsley with an automobile roof rack. Pugsley uses an offset 135mm-spaced fork, so it won't simply plug into a fork-mount type of rack. Some racks will allow the retrofit of a longer dummy axle to accommodate the wider-than-standard fork dropout spacing. But it makes more sense, in my opinion, to leave the car rack alone and build a removable adapter instead. That way, the rack can be used for 100mm-spaced and Pug-spaced forks without having to change hardware. Hurricane Components makes several Fork Up adapters to fit a wide range of bicycle forks. I chose to modify their Riser model to work with a Pugsley fork. After knocking out the stock plugs, I shortened the disc-side plug 4.5mm (the thickness of the hub locknut), drilled it out to accept a 10mm axle, and reinstalled it into the Riser center tube. A new drive-side plug was made from 25.4mm (1") round aluminum stock. It was sized to stick out 40.5mm from the end of the 80mm-wide Riser center tube. Here's how it adds up: 4.5mm locknut + 40.5mm drive-side plug + 80mm center tube + 5.5mm disc-side plug + 4.5mm locknut = 135mm spacing. A 10 x 1 x 146mm Wheels Manufacturing axle holds it all together, and a rear Shimano QR skewer keeps the Pug fork clamped to the adapter assembly. Most wheel tray/fork mount style bike racks don't readily fit our Endomorph tire, but a toe strap can be used to cinch down your rear Pugsley wheel to the rack wheel tray. The tire won't fit within the tray, but it should stay centered if the toe strap is adequately tightened. A wheel tray Endomorph adapter would probably be an easy thing to make, but I'm not sure it's necessary. -----
Brother David Sunshine's avatar

About Brother David Sunshine

Dave Gray is a product designer at Surly Bikes and was the second employee to be brought into the Surly fold. Dave is the brain behind such products as the Big Dummy, Pugsley, 24 Pack Rack, and numerous other cargo related items. Dave has a penchant for carrying things with his bike many people would have difficulty fitting into their car. To say Dave knows cargo would be a gross understatement. Dave is like the mist, briefly descending, only to disappear into the forest again, but if you need to find him, head to the deep slop and listen for the sounds of freestyling. That is where you’ll find him.

Continued Bloggage

im - 11/27/2006 10:05:00…

Hello. Do you like to suffer? You do? Then you've probably dreamt about the TransIowa race. Most of you inclined to participate have likely already been following this year's TransIowa developments, but Kerkove and Guitar Ted want you slackers to know that version 3.0 is happening in April, registration is…

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im - 11/13/2006 10:50:00…

I'm sure some of you out there like those fancy "clothiers" that supply at high mark-up the appearance of a life you don't actually live. You know what I'm talking about... places like Abercrombie&Fitch or J.Crew, where for only hundreds and hundreds of dollars you too can look sort of…

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