Southern Cross

“The story of Ben’s bike”

The idea

What started out as a simple statement, one uttered almost daily by every cyclist regardless of discipline or ability, ended up as almost a year of delicious obsession along with all the associated agony and ecstasy. The statement?

“I totally need another bike.”

I already have a MTB and a 10-year-old road bike, but have found that touring on the MTB can be really slow, and the road bike is just too light for anything other than smooth unbroken tar, something not in ready supply here where I live in South East Asia.

I troll the websites, sifting through the sometimes questionable nuances contained in the different categories; endurance, cycle cross, adventure, gravel, all road, randonneur, monster cross. For the most part it’s a case of “same same – but different” but eventually I can capture the basic concept of what I am looking for in 2 similar bikes, the Ninner RLT and the Jamis renegade. Both are steel framed, fast gravel bikes, meaning they can accommodate wide tires, have endurance geometry but with a slightly lower center of gravity and tuned for stability. The problem with both, is that there is something missing. The “something” I decide, is personality.

So I start thinking about the role that cycling has played throughout my life and how, much like music, it has been the backing track to my decades on this earth.

My dad at full tilt on his track bike - 1940's

Of course it didn’t really start with me at all, my dad had his own cycling backtrack to a very different life. He was a track cyclist and I have this awesome photo of him in full flight taken around the 1940’s. That photo encapsulates the passion and spirit of road racing that was as present back then, as it is in todays top professional cyclists almost 80 year later.

My first bike was a "Cape-ads" special which my dad and I put together from bits and pieces, a frame for $1,50 and a set of wheels for $0.5 We hand painted it blue and to finish it off, my dad fitted it with an old Stermy Archer 3 speed gearbox. I loved the personal freedom that bicycle afforded me during a time in my life when everything was governed by rules and limitations. “Just going for a ride on my bike” was always met with a positive response and motherly concern regardless of the reality of what exactly that meant. What it did mean, was the freedom to head out on my own, to follow a route created in my own head, to turn left or right wherever I chose and more often that not, to journey clear around the Cape peninsula from Indian to Atlantic oceans, along some of the most scenic areas in the world, up and over iconic passes to arrive home well into the afternoon, sunburned, windblown and famished. All this as a mere 12 years old.

In Matric (Grade 12), I got my very first brand new bike, A red Armstrong 10 speed racing bike with white bar tape. I can still clearly see it in my mind's eye and recall the rubbery smell of its newness as it sat impatiently next to my bed on that night before my first ride on her. I swear I slept through that entire night with a huge grin stretched across my pimpled face.

Now, many decades have passed me by. I am an adult with the same illusion of independence and self control as everyone else, yet the reasons for my continued and increasing passion and pleasure of cycling are still exactly the same as they were 44 years earlier as a shy 12-year-old boy from Plumstead in the Western Cape of South Africa.

As the waters of that endless river flowed under the bridge of my life, I went on to cycle the Freedom Challenge race across South Africa twice, winning it in 2006, cycled across the Karoo in 2007 and then completed two Ironman events in PE during 2008 / 2009. Between 2010 and 2014 I cycled long distances in Thailand, Laos, China and Malaysia and in 2015 my son and I cycled across Bhutan and on to Kathmandu in Nepal. Get this though, my Son did it on an unmodified BMX while I accompanied him on my mountain bike.

Dylan on his BMX during our trip across Bhutan and into Nepal

After seeing the Himalaya mountains for the first time in the distance during that trip, I went back to Nepal in 2016 and cycled from Kathmandu up near to the top of the Annapurna circuit at 4,300 MASL, again on my MTB. I don’t mention these things here to brag, but because for a very small and painfully unconfident boy from Plumstead South Africa, the road has been hard, and these are some of my very precious victories.

So I start to think about the idea of a custom bike, a bike that will be a celebration and a tribute to three generation of cycling in my family, and that’s when quite by chance I come across the website of a custom bike builder in Cape Town, David Mercer. David happens to live not too far from my family home, and very close to the merchant I once frequented during my dazed and confused years, but that’s another story altogether.

When I write my request to David, I don’t have a clue if he will be willing to undertake my project, what the process will involve or if I can even afford it. The easy part is that I don’t need to decide what bike I need, only what I want the bike to do for me. So I subject David to a long drawn out history of my families cycling history complete with photos, and a final statement which really should have put David off the project right from the start.

“It must be Stevie Ray Vaughn and not Eric Clapton, Evanescence and not Adele”

I don’t know, but I think one has to be a psychologist to be a be a good custom bike builder.

When David’s reply arrives, I am almost to nervous to read it, what if there are certain credentials needed, some or other unwritten “club’ membership, an elite this or that? Of course there is nothing of the sort, and he seams to have enjoyed the history and photos of my families cycling exploits. He outlines the basic pricing structure and then in more cautious tones points out that there will be a waiting period of around 6 – 8 months. Instead of been put off by this, I am sold. Firstly; from a financial point of view it gives me the time I need to save for the project, secondly; it confirms to me that this is a genuine custom process, not a semi- factory custom set up where you choose options from a website, and thirdly; it provides me with time to really explore and solidify my thinking around the bike design concept, components, paint scheme etc. I write back and ask David to please put me on the waiting list.

Its December 2016.

Right from the start, there are a number of challenges facing me. Although the Cape Province is my home, I live and work in the small South East Asian country of Laos (near Vietnam and Thailand) as a protected areas management advisor. Everything will need to be done remotely, including all my measurements, frame design detailing as well as ordering all the components and having them in Cape Town in time for the final build. My deadline to collect the bike will be in August, during my home leave.

I confirm with David that the bike will definitely be ready by then, pay my deposit and book my flights.

…and so the journey begins:

My design brief

“I am looking for a bike on which I can travel fast for many days or even weeks at a time over any road conditions, and take along some camping stuff if I want to…….oh, and it must look super damn awesome as well”

Functionally there are a few things I do know that I want;

Steel frame and fork – I could go with a carbon fork, but then why not just a full carbon bike and be done with it.
Endurance geometry – Not a racer, but also not a Surly.
Ability to carry light loads on a rear carrier and panier set. – I don’t really like anything on my bikes, but maybe one day I’ll want to take along a tent and some beer, who knows.
Frame and rims should support tire size 28mm - 45mm with adequate clearance for mud and gunk - For the “over any road conditions” part of the recipe.
Good climbing performance and gearing adequate for long steep assents. – Compact crank and at least a 32 cassette at the back.
Stable on long loose gravel descents. – Because peeling at speed hurts a lot.
Strong consistent braking under all weather and road conditions. – because peeling at speed hurts a lot.

I do loads of reading up and watching YouTube videos explaining the nuances of frame design and different geometries, but too often I get sidetracked by things like “Worlds top 10 funniest pogo stick fails”, so I end up leaving these details to David, who has a far better understanding of exactly how many cm from the ground, the center of the BB should be.

7 Months is a long time to wait though, especially for me who thinks that fidget hand spinners are the best thing since laser pointers. I go down many side alleys during the first few months, at one stage coming up with the idea of a modern version of my dad’s old track bike.

“Ben!...remember the deal…….no retro!”

Finally, after 6 months of painful waiting, I get an e-mail from David with a set of CAD drawings attached. I am over the moon, this is actually happening! David asks me to check out the geometry and let him know what I think, and what I would like changed.

“I’m not so sure about that stack ratio David”, yeah right! But I do have some input. I have a very comfortable endurance road bike I am currently riding, so I send David some measurements as a means of comparison. He makes some small adjustments and sends me an updated set of drawings. I’m happy if he’s happy and so the design is locked in.

The components:

Now this I can do something about, let the fun begin!

I have already decided that I will order all my components from international online suppliers due to the fact that I am earning in USD and thus enjoy a more favorable exchange rate than if buying in South Africa.

I search an online cycle store called “JensonUSA” who have an awesome range of components, and am soon populating and repopulating the shopping cart in simulated shopping sprees. SRAM red this and Thomson that, Chris King there and Cane Creek over here, carbon and titanium, and so that would be…………whaaaat!!!!, $6,500! Oh well, no problem, empty cart and start again.

Its great fun and the game goes on for months. It’s not just a game though, because along the way I am learning a lot about what makes a good component as apposed to what makes an expensive component. I learn the difference between flat mount and post mount disc brakes, solid and ice-tech brake rotors, 1X and 2X groupsets, ceramic v standard bearings, rolling resistance of wider tires, stiffness and compliance, aero V lightness, compact V standard. I have spreadsheets with pie charts and multi-colored bar graphs, specification comparisons, budget templates and exchange rates. Options, OMG there are so many, many, many options!

Finally, a month before the build is due, I have my basket ready for the till. Budget wise, its at the very limit of my resources:

SRAM FORCE 22
THOMSON seat post and stem
STELLA ITALIA saddle
SALSA cowbell handle bars
SRAM HYDRO disc brakes
CRISS KING BB and Headset
HOPE PRO HUBS and STANS no tubes wheel sets
MAXXIS Rambler 40mm tires
HOPE industry flat peddles

With my heart in my throat, I hit,” pay now” and boom, there it all goes swirling down the plughole. But actually it doesn’t go anywhere at all, because the next day I get a message that my order is on hold till I contact the accounts department. Great, I’m in Asia and they in the States, literally opposite sides of the world. After a few 2 am cyber- rendezvous, I am told that I need to get an 8 digit authorizing code from my bank before they can charge and ship my order. What? Where? How? When I phone my bank here in Laos, they don’t have a clue as to what I’m on about. Days pass.

I start searching again, ChainReactionCycles, half the stuff I need is out of stock. Evans Cycles UK, but they have a limited range of SRAM road group sets. Maybe, but what they do have is a massive special on Shimano Ultegra 22 speed. I wonder, does it really have to be SRAM? I love SRAM, but can I really justify spending the $700 price difference to get it, when in reality there is nothing at shabby about a Shimano Ultegra group set. Sure, its not as sexy, but it should all be covered in dirt half the time anyway.

I manage to cancel my order with Jensen who are very helpful and understanding, and soon I have a completely new basket full of goodies with Evens Cycles. This time, when I hit “Pay now”, its with a much lighter heart and everything runs like clockwork, no bank authorization numbers needed, hardly any postage charges. It’s the right decision, and I can even splash out on a carbon seat post while remaining within budget. Its almost unbelievable how quick and efficient their service is, and within 24 hours, my ever helpful and long suffering sister in Cape Town lets me know that the first package is waiting for her at customs. One package in the set of three takes a bit longer, but that’s thanks to our customs office in Johannesburg.

I feel really happy with my choices now, Italian cockpit, British bearings, and Japanese group set.

My final choice then:

SHIMANO 6800 Ultegra 22 speed group-set (11/32 cassette and 50/34 crank)
SHIMANO Ultegra flat mount hydraulic disc brakes
HOPE ceramic BB
HOPE XC Headset
3T stealth stem
3T alloy cycle cross handlebars
DEDA carbon seat post
STELLA ITALIA max elite gel flow saddle

Praphreut from Bok Bok cycles in Bangkok showing appreciation for the beer I brought them from Laos when discussing my wheel-set

I have made contact with an enthusiastic and talented couple of guys in Bangkok who are passionate about bike packing and cycle touring. They own a small bike shop named “BokBok Bikes” specialising in Surly bikes and touring equipment, and they also build wheels. On one of my trips to Bangkok, I take them a couple of Beerlao, and we discuss a wheel set for my bike. After some research and with their advice we agree on the following set up which will take a wide range of tire, from 28mm all the way through to 45mm.

The final wheel set then:

VELOCITY Aileron disc rims
HOPE Pro 4 Hubs, front and rear
32 spokes
Brass nipples

I arrange to collect them on my way through Bangkok in August during my home visit.

The color scheme

In terms of the overall project, this aspect has to be the least important, yet at the same time has the greatest potential to destroy the careful thought and craftsmanship that will go into the bike.

Once again, it’s months of soul searching coupled with a long series of lessons and learning. I download 1000’s of bike pic’s and finally discover a website called “100 brilliant color combinations”. Through this site I discover color combinations, RGB sliders and Hex color # formula. Initially I try to incorporate important bits of my life into the design, green and gold for my work in conservation, blue and white for my surfing and sailing. I then go “black” and later “bright tropical”…..aghh!! too much choice.

Eventually I print out a frame drawing from David’s CAD design and buy a few sets of color crayons and cocci pens to try out my main ideas. I’m coloring in again, something that I haven’t done since primary school days. I never realized just how therapeutic and creatively rewarding the process would be. My choice is reduced to three main color schemes and a simple design consisting of a slash running diagonally across the frame from the base of the fork up to the top of the rear wheel.

The three color choices, either of which would work fantastically well,

African sunset
Tropical fun
Bright and tropical

My final choice made a week before David starts on the frame, is African Sunset.

Tropical fun

Bright and tropical

My final choice made a week before David starts on the frame is African Sunset.

Frame and fork build

Once again there are “options” and the research and learning continues.

In an e-mail to me, David asks: “Do you want Lugs, fillet brazing, a combination of the two or bi-laminate joinery?”

“Would any of those be available in strawberry?” I want to ask.

After some research I realize that I have more chance of ending up with a great build if I leave this up to David than if I come in at a tangent with my own or someone else’s ideas. David has the concept for my bike in his head, probably before he ever picks up the grinder, so I leave these choices to him.

My research on the frame material David wants to use for the bike, Columbus Zona, states as follows: “This tube set produces a bike of moderate weight and notable strength with a compliant steel ride”. Sounds good to me.

So the conclusion of a chain of e-mails correspondence, results in the following frame details:

FRAME MATERIAL - Columbus Zona
RACK MOUNTS - Rear only
DISC MOUNTS - Flat mount
AXIL’S - Through axle’s front and rear
MUD GUARD MOUNTS - Front and rear
CABLE ROUTING – Internal for brake cables, external for gears
BOTTLE CAGE BOSSES - For 2 traditionally placed
MERCER HEAD BADGE - Polished brass
FORK - Straight blade, to accommodate flat mounts.
JOINERY - Lugs / Fillet brazing / bi-laminate - Builder’s choice.
FRAME BADGE - Brass

Bikes name

David explains to me that on every bike he builds, he attaches a brass plaque under the BB with the Nickname / Bikes name / owners name / stenciled onto it. Thinking that he means there is space for all three of the above options, I go for my favorite quotation:

“All that is gold does not glitter, Not all those who wander are lost"

“Er….. no Ben, not an historical novel, just a word or two!”.

This is a bit more difficult; what can I do, combination of bits of my children’s names, my dog, family nicknames, cycling puns, I don’t know, something around exploration and adventure, the Southern Ocean, Orion’s belt, Southern Cross, hey!

“Southern Cross”

Elements of navigation and exploration, South Africa implied, and even a bit of a pun on the word "cross"

I like that a lot.

The build

I notice that on David’s website he has a blog page where he posts updates through Instagram of his current builds. Here I get glimpses of a frame filet, or detailing of a special dropout, sometimes even a completed frame. I also notice that there is usually a link to the owner’s Instagram account.

I don’t want to be left out, so before David starts on my build, I dust off my dormant Instagram account and dump a stash of my better cycling related and other photos into the account. Why? Well I wouldn’t go to a social event only in a pair of undies right?

Through axle's on Southern Cross - Photo - David Mercer

Living so far away from Cape Town, the daily posts on Instagram are my only link to the build process when it finally starts in July, I savor every photo update, look! a through axil, a fillet join, the lathe that made the through axle. Its more art than steel work really, ……oh and look, there’s a photo of David going on holiday with his family!

“Er, whaaaaaaaat! Oi! David! …the Southern Cross!....what about the welding and grinding and sanding of stuff!”

I don’t obviously say that, but I do think it for a short moment before another thought comes to mind. Imagine how much more relaxed and focused he’s going to be when he comes BACK from leave and continues to work on my bike! Ok then, breathe in the fresh air and don’t let the kids stress you out!

I think that been a custom frame builder must take a LOT of patience.

Final countdown

My completed front fork with though axel's, internal cable routing and flat mounts. Photo - David Mercer

Just when I have all but given up hope, “boom” Instagram post from David of my completed fork, resplendent in its rawness, through axil, flat mounts, internal cable routing, all in all, a work of art.

My sister drops off the last few components and David asks “Plain or Metallic finish?”

Not sure, mmmm, ah what the hang, let its light shine……” Metallic”

“Excellent choice” comes back the reply.

I’m getting the hang of this, what am I going to do when the project is finished, what options will I have then, what new riddles to solve, what choices to make?

T – 12

One of my rims had been damaged in transit, so now the Thailand wheel builder can’t build my wheel set. Ok no problem, build the rear as spec, and build the front using a test rim they have lying around. When I pass through Bangkok on the way home, they will rebuild the front with the spec rim which is already on the way from the manufacturer. Solved, next?

T - 11

The completed frame prior to painting. Photo - David Mercer

Finally, a full frame photo of Southern Cross all ready for her appointment with the painter. The detailing in one of the photo’s David posts is truly fantastic, a deeply scalloped side tacked seat cluster, and just peeking out, I can see the brass frame badge.

T – 10

Passing through Bangkok on my way to cape Town, I stop off to pick up my wheel set from Bok Bok Bikes, walking the 10km round trip through the hot steamy streets to their small shop, crammed to the gills with Surly bike frames, wheel building equipment and boxes of new arrivals. I could have sourced the wheels from Cape Town easily enough, but that’s not the point. These guys are passionate about cycling and they often close shop just to go cycling. They NEVER open early, but when they work, its usually till well past 11:00pm. They say they are the “vampire bike shop”.

When I get back to my guest house, I place the rims on my bed and take a photo. looking at the image later, I see that my rims have miraculously morphed into a minion, BANANA!

I’m think I’m finally getting the idea of what a custom bike is all about.

T – 7

Having finally arrived in Cape Town, I get to meet David when I go to hand over the wheels and the last few items for the build. Its fantastic to finally meet him, and he shows me around his workshop where he is currently working on his first full suspension bike.

My frame is still with the painter, and it appears from my conversation with David that the actual color scheme has turned out somewhat different to my original design drawings. I am a little concerned and remember the months of experimentation and painful indecision. Could it all have been for naught? Could I end up with an eyesore? Tomorrow I will find out…….

T – 4

Me, proud owner of one custom build and painted cross bike.

On Tuesday afternoon, David places the completed frame, freshly returned from the painter, into my hands. The craftsmanship is truly amazing, from the seamless fillet’s through to the sculptured seat stay cluster, the custom through axel-points and the internal cable routing. I turn the frame over and on the bottom of the BB is a brass plaque with the words SOUTHERN CROSS stamped out in bold letters.

The "Cape Rock Pigeon" painted up by Jared of BMC.

The painting is superb, the slight metallic paint creating a soft finish that appears to blunt any sharp features, creating more a molded form than a collection of individual tubes. Like David, the painter, Jared from BMC is an artist, and has added his own personal touch to the frame. Taking me out into the daylight of the garden outside the workshop, David tells me to look closer at the frame badge. I squint in the bright sunlight and there, with delicate artwork Jared has transformed the Dove (The traditional logo of Columbus Zona) into a Cape Rock Pigeon. It’s a small detail, but serves to pull together many of the individual elements creating the African sunset theme.

There is a slight problem though, in that the color scheme is different, by quite a long way, from my original design. It’s a bit of a “lost in translation” issue during the color coding conversions needed. The main noticeable difference is the top band of color which is now a definite orange, as apposed to the original burnt red. I think that overall, the color scheme still works, but there is a slight disappointment in that I loved that red, and would probably never have chosen orange for the top of the bike. I think its gong to be something that grows on me, and its certainly does not detract anything from the overall feel and context of the bike.

Its now a case of waiting for David to build up the bike and for me to take it for its first ride.

D- Day

Finally, Southern Cross dressed and rearing to go places.

Finally, the day has arrived, and it’s a cold day, much needed rain splattering on the windscreen. David welcomes me at the door, and there in the courtyard of his house stands Southern Cross. The first thing that hits me, is that this is a bike that means business, the wide tires, generous geometry and spacious cockpit lends an air of open spaces, gravel tracks leading into infinity under a star studded sky. Secondly, it is evident that the sum of all its individual components, frame design and color scheme have come together in such a way as to transcend any preconceived mental images that had developed in my mind, and now for the first time since seeing the fame a few days ago, the color scheme works perfectly, it all just makes sense.

Some of the beautiful detailing, here the deeply scalloped side tacked seat cluster.

David, takes time to go over the bike with me, carefully highlighting any component fit issues or areas that may need closer attention during use. I get the impression that he is as proud of Southern Cross as I am, and I feel a healthy sense of responsibility, not only to care for her, but to ensure that she is used as intended, as often as possible and in as many weird and marvelous places around the globe. I pack the bike up in the back of my car, and set out on the road.

First blood

D Day + 1

Its 5 AM and I am lying under a mountain of down in a guest house in Prince Albert, just at the foot of the Swartberg Pass, my chosen venue for Southern Cross’s first ride. The plan is to take a quick spin to the top of the pass, take a few photos, and then descend quickly before the forecasted heavy rains and snow made life at the top a touch unpleasant.

First blood along the base of the Swartberg mountains.

Unfortunately, my plans are not to be, due to a long term closure of the pass for repair after a flood destroyed a large section of the road. No amount of sweet talking can get me past the gate guards and so I have to abandon the pass for a not so unpleasant gravel grind all along the base of the Swartberg mountains.

Modeling in front of an old Karoo sheep shed.

As with any new bike, I ride out the first few kilometers with a multi-tool in my hand, making fine adjustments to my riding position, saddle height, bar rotation etc. Thanks to the DEDA double saddle clamp system, I am unable to level the saddle, but everything else is spot on by the end of the adjustment period.

So then, my top 3 first impressions:

1. Steel rocks as a frame material – I totally forgot just how compliant steel is, my last steel bike was a ridged fork mountain bike which I THRASHED around all the forest tracks of Nuweberg and Grabouw 22 years previously.

2. Cross bikes are very fast on downhill section. – OMG! There is just something very wrong about descending at high speed on loose gravel while your sweaty palms are wrapped around a frigging DROP BAR!

3. Southern Cross is a thoroughbred – Something about the geometry, the wide bars and slightly more slammed stem that I am used to, gives me the impression that she is galloping across the landscape, especially on an ever so slight downhill run, she has definite poise and grace, and a very willing response to the lightest touch of the whip.

D-Day + 10

After:

1 X Rental car self drive
1 X Domestic flight
3 X International flights
2 X Taxi’s
1 X Tuk Tuk
1 X back of a pick up

Southern cross is finally unbagged, re-assembled and leaning rather self consciously up against the window of my study feeling quite a bit out of place during a time of heavy monsoon rains and thunderstorms, gooey orange mud and luminescent green rice fields.

Southern Cross looking rather out against the background of Lao rice paddies.

She has survived the journey pretty well, although due to ignorance on my part, I managed to crunch up the washer on the rear through axel, not realizing there is a "lip" the washer needs to mount first. Nothing that a hammer and round file can’t rectify though, and so all is well that ends well.

Beginnings and ends

Looking at her in this new context, I have the distinct impression that like me, she is pinning, ever so quietly for the dry dusty gravel of the Little Karoo, blown like chalk across a starker landscape.

I am reminded once again of the realities of “living our dreams” and the reasons why so few ever realize them, for its not within the limited finances, lack of opportunities or fear of the unknown that they are found, but rather they are hidden within the subtle realities of what we will need to let go off, that whittles down the masses to the few.

Something that David said to me while we were chatting over the bike stuck with me like hot nylon to naked flesh.

“Looking into the future of my custom bike building business, I could go more exclusive and thus more expensive, but then that would cut out the people that would probably most benefit from having a custom built bike”

I am not sure that David fully understands the significance of what he provides to people like myself. For me, he provides the wings that allow me to sore within the rather selfish and sometimes unrealistic dreams that continually race around my head, but its really within these dreams that I find the very essence of my existence, the meaning I ascribe to the purpose of my breath.

Looking back over my life, I can’t help but draw parallels and notice connecting points between the life of my father, that of my Son and my own, like the warping of time and space to bring three different dimensions of the same universe to converge into a single energy and then, as if unable to contain our collective individuality, to explode outwards with an ever increasing and widening trajectory that was, is and will continue to become our own personal journey through life itself.

I think, that to be a true custom bike builder, one may just need to be a Philosopher.