2001 Orange Zero retro trials build.

[Luke_Coupe]

So I thought it was about time to upload some pictures of my current project. 

I’ve had many trials bikes over the years and over the various lock downs we’ve had, I was looking at a few groups and it made me feel very nostalgic. 

I will try and update this in order of my camera roll.  

So, step 1. Try and source the frame. I originally wanted a pashley 26mhz but at the time I couldn’t find one. A frame popped up on Facebook market place and a deal was made. Before buying this frame i actually never knew they came in 14”, I’ve only ever seen the 11” version. After some messages to people and a few Google searches, it’s confirmed that they did come in 14” and they’re incredibly rare.

So here she is, 2001 14” Orange Zero Petr Kraus replica frame. 

 

I’ve never been keen on black frames. The plan is to have the decals re made and the frame painted white.

[Luke_Coupe]

Now the frame has been sourced. It was time to hunt for the parts to build this up. 

Cannondale fatty r forks
Magura hs33 racelines
Middleburn rs7 pro trials cranks
Mavic d521
X-lite phatso
Azonic bars
Irc kujos
Hope hubs
Kore stem
Mini seat
Group set. 

 

[Luke_Coupe]

After getting the fatty r forks, the steerer was short by about 15mm. 

Time to hunt for a second pair. These forks are very hard to find these days, but I managed to find another pair with 200mm steerer. Happy days. 

 

 

[Luke_Coupe]

When it comes to bike restorations I like my parts to look new. Trying to source near new magura hs33 racelines are a hard task, so I thought I’d have mine re painted.

Luckily retrodecals have the decals on file.

Next job, strip 2 sets of hs33’s ready for paint.

Once the brakes were dissembled, the dreaded tpa’s had snapped on all leavers!
 

 

 

 

 

[Luke_Coupe]

With the frame, forks and all the magura bits off to paint it was time to source the other bits for the project.
 

I went on a massive spending spree and bought more than I should have. But there’s a reason for this, I have decided to make a few retro builds.

Nearly NOS tioga factory dh 2.3’s for £6!
 

 

NOS LX shifters.

NOS fsa power pro cranks.

 

 

Mr Crud DCD.

 

More azonic bars.

And a couple more sets of the famous Rob Warner BASE jump pedals.
 

[Luke_Coupe]

I decided to split all the phatso’s I had bought so they’re rim only.

 

Another Sora short cage rear mech. 
 

 

Mk1 DCD. 
 

 

Even though it’s a retro build, I did go with a modern headset.

 

Some lovely 36h hope bulb hubs.

And probably one of the hardest tyres to find in really good condition. IRC Kujo DH 2.35.

 

 

Edited December 20, 2021 by Luke_Coupe

[Luke_Coupe]

Whilst waiting for the frame and other parts to come back from paint. I decided I wanted to build another project.

I wanted to build a martyn Ashton replica, so I found an old m600 in 16” for £30. Perfect for a replica.
 

 

Literally a week after this frame had turned up, I found myself driving to Manchester for the real deal. Martyn Ashton signature cannondale. I will start another thread for these builds though.
 

 

 

 

 

[Luke_Coupe]

At this point in the build, I’m still waiting for most of the stuff back from paint. 

So another spending spree happened. 

I took the middleburns off the Ashton and acquired another set cheaply. I have a plan for all the cranks…….
 

 

 

 

The plan for the crank arms is to have them re ground and re polished. 2x pairs will be brushed and the other pair will be mirror polished. 


So I took the bash guards to a local machine shop to have them shaved, turned and have a knurl around the edge. The results……..
 

 

 

Another minter of a DCD. 
 

And another lucky score. Another pair of IRC Kujo DH, this time 2.25. 

 

[Luke_Coupe]

Next part of the project was to have the bash guards anodised with a few other bits. 

All the bits rounded up and off they went…….
 

 

 

 

Some VGC x-lite crank bolts had arrived.
 

 

And I finally got the cranks back from being polished. It cost me £50 for all 3 pairs to be polished, I’ll let the pictures do the taking.

 

 

Next step of the project was a tough one. Re-create the original orange zero petr kraus decals. I was very lucky that John over at orange sent me all the original files to have the decals made. He recommended a company and the process began. I think they look amazing. 
 

 

And last but not least, my parts had arrived back from anodising.
 

[Luke_Coupe]

The day had finally arrived. I got the call to say all my parts from paint were ready. So I wasted no time.
 

 

 

 

Crank and bash ring paired together.
 

 

Some lovely UN52 & UN72 bottom brackets.
 

 

Now the fun can begin. Get the decals on the frame…..
 

 

 

And time to start dressing the bike up.
 

[Luke_Coupe]

Since the last update I have mainly just been sourcing more parts and deciding which wheel/hub choice I’m going to use.

I have a few options and even now, I’m still undecided.

Weather or not this particular rim will be used on the Ashton or the zero, i knew I needed one. In my previous post you’ll notice I had 3 black x-lite phatso’s. I always wanted a silver one. I had been searching for at least 6 months and finally. 
 

 

 

Another set of cannondale fatty r forks. Now these have a 220mm steerer and will replace the fatty’s on the zero. Mainly because I’ll use the shortest steerer pair on the Ashton which has a shorter headtube. It saves me shortening a pair of forks when it’s not needed.
 

 

A NOS mbuk watch strap.
 

 

A NOS x-lite stem cap.
 

 

Another set of some azonic pdw’s.
 

 

The line up of forks.
 

 

Time to re-create the phatso stickers.
 

And finally! Not really an update I wanted to broadcast, but I ended up stripping the zero frame completely to be re painted.

Unfortunately I suffer from ocd and a few small imperfections on the frame annoyed me, plus I put a chip in the headtube. The original paint job didn’t cost anything, but the time and effort had already been spent.

Here she is stripped, ready for an acid bath, sand blast and this time, powder coat! I went with powder coating this time as it’s more durable.

[Luke_Coupe]

Now that I’m waiting for the frame to come back, it was time to find the period correct headtube badge as it was missing. 

I had put a wanted ad up on an orange group on Facebook, and within a day I had found a NOS headtube badge. Result!
 

 

Yep, you guessed it, more parts. 

I know it’s not period correct, but trying to source parts in mint condition/NOS can be challenging, especially hope hubs. So In the end, I went with the modern hope stuff. 

Head spacers. 
 

 

Seat clamp. 
 

 

Pro 4 36h front and rear hubs with matching quick releases. These took 12 weeks to come. 

 

 

Some fatty r decals.

 

I had previously sourced a NOS raceline horseshoe booster and I was luckily enough to find another. 
 

 

And finally, we have all the parts back from powder coating
 

 

 

[Luke_Coupe]

We’re now all caught up with the project.

It’s been a few weeks since I had the frame back. Due to work and family commitments, I haven’t had anytime to work on the frame.

Last weekend I had a Saturday morning to work on the bike and I wasted no time.

Freshly powder coated frame.
 

 

The painful process of putting the decals on the frame, for the second time lol. Luckily I was sent 2 sets.

 

 

 

NOS headtube badge. I’ll leave the film still on it.
 

 

Put the white fatty r decals on the freshly powder coated forks.
 

 

And all my magura bits and pieces looking very nice.
 

[Luke_Coupe]

Later that evening I managed to sneak back into the garage to do some more work to the bike. 

Time to rebuild the maguras back up
 

 

Remember all them broken TPA’s? Solved!

 

 

We’re getting there!

 

 

One set complete.

 

 

And mounted.

 

 

I’m seriously impressed with how these have turned out so far.

 

[Luke_Coupe]

So In the week a few parts had arrived. 

The finer details. 

Orange chain stay protector and a new mech hanger. I had my existing one powder coated, and you guessed it, it didn’t fit anymore lol. 
 

 

 

 

1999 Phatso vs 2021 freshly powder coated rim with new decals.
 

 

 

[Luke_Coupe]

Another delivery this week. Possibly my favourite part I now own.

If you was ever into trials in the late 90’s and early 00’s, these tyres were the ones to have. I always wanted the tyres back in the day, but unfortunately I never ran them as I preferred tioga factory dh’s. I have tried to source these before and had no luck.

But I got lucky this time.

NOS IRC El Gato’s.

 

[Luke_Coupe]

Some more upgrades have arrived for the maguras. 

Uprated metal leaver pistons and uprated springs.
 

 

And replacement parts to replace some worn out or old looking parts.
 

[Ross McArthur]

Love an alloy piston upgrade.

[DJEHB]

Best thread in a long time. Keep the updates coming on any future projects please 

[AdamR28]

The dedication to detail here is nothing short of astounding. You've just taken me back in time 20 years  brilliant work!

[Luke_Coupe]

22 hours ago, Ross McArthur said:

Love an alloy piston upgrade.

I’ll be honest, it’ll be my first time using them Ross. 

[Luke_Coupe]

12 hours ago, DJEHB said:

Best thread in a long time. Keep the updates coming on any future projects please 

Thank you so much mate. I’ll update in a few minutes. 

[Luke_Coupe]

12 hours ago, AdamR28 said:

The dedication to detail here is nothing short of astounding. You've just taken me back in time 20 years  brilliant work!

Thank you Adam. That’s how I felt whist looking at everyone else’s retro rides during lockdown. 

[Luke_Coupe]

So I had another play about on the zero a few days ago and it didn’t exactly go to plan whilst mounting the maguras. 

The powder coat on the mounts is way too thick. I must have spent an hour with the dremmel sanding them to fit, but it didn’t work. Even snapped some mounts. So I’ve had to rummage through the spares box and use some old mounts. At least I get an idea of what they look like. 

The plan now is to get these old mounts wet sprayed or try and find some NOS mounts. 

Also fitted the up rated metal pistons and springs, plazmatic pads, new pivot bolts and leaver clamp bolts.

 

 

 

[Ross McArthur]

Is there nostalgic reasons for wanting to run the quick release on the mounts? Why not chuck that and just run a bolt like on the non drive side. Would look so much cleaner and takes away the silver from the lovely lumi on black look.