Carbon Fiber Project #1

2012 Rocky Mountain Element

My aluminum 2012 Rocky Mountain Element needs an upgrade. Well, it doesn't really need one; it rides just fine. But, in the spirit of finding a suitable part for this project, sure the bike NEEDS an upgrade. This is a full suspension bike, so it consists of a front 'triangle' with 2 large links extending to support (or, suspending) the rear wheel.

The front triangle must interface with the crank bearings, the headset bearings, the seat post, and the rear suspension links at 2 locations. As such it requires a high degree of dimensional accuracy. The frame is dynamically stressed with all sorts of exciting loads, and it damn sure serves a purpose: getting me safely down the mountain ...expeditiously. So a bike frame really checks all the boxes for an ideal composite project.

And I accept the challenge. As my selected learning exercise, I will build a carbon fiber front triangle for my mountain bike to replace the current aluminum one. The carbon frame will need to mimic the fit geometry of the existing frame and duplicate the suspension geometry and connections. The bottom bracket, head tube, seat tube, etc must also be identical to original. This way I can simply swap over all the components and rear suspension links.

I've built bike frames before, in steel. So I'm aware of what is important for the frame itself while being unfamiliar with the new construction media. This is perfect for learning composite construction because I won't be 'figuring out' bicycle frame construction at the same time.

I've also build a full suspension before, from steel. The frame functioned as intended, but the geometry I designed quite honestly sucked ass. So replacing an existing frame, again, focuses my efforts on learning composites rather than dickering with full suspension geometries, shock rates, pivot design, etc.