Ron Damon

This thread is dedicated to my custom self-build of a touring, around-town utility folding bike based on a FnHon Storm chromoly frame and Al-alloy fork.
​​​​​








​​​​​​
​​​​​​The FnHon Storm frameset (frame, fork & seatpost collar) weighs about 3.2kg, with a wheelbase of 102cm, top tube of 58cm and chainstay of 40cm in length.

Frameset - total cost: $200
​​​​​

CEBEP

WTF another build? I don’t want to buy another folding bike!

I guess it becomes a habit. I’m sure it will also be another awesome looking build which looks to have disk brakes. Good luck.

Ron Damon

Yeah, thanks...It's just a frame for now...I'm a bit of a frame collector. It doesn't necessarily mean it will get built any time soon or, perhaps even, at all.

There's now a sweet Titanium finish Storm available. I may just have to acquire one too.


The FnHon Storm (frame, fork & seatpost collar) weighs about 3.2kg. The wheelbase is a relatively long 102cm, longer than what I prefer, so there's that.

​​​​​​​

CEBEP

Is it an actual titanium or just a silver paint? Or is it bare metal with protective coating only? Looks pretty good.

Ron Damon

​​​​​It is 'titanium' color only.

CEBEP

I think it would be a good idea to make one of titanium if they can manage the flex. Titanium frame and fork, Ti seatposts are available, maybe Ti handlebar stem. Should be incredibly light and probably cost less than dedicated Ti folding bikes.

pinholecam

Those thin stays make it look like a steel bike.
Looks real nice.

Ron Damon

The wheels consist of:

• Litepro ISO406 (20") K-Fun disc brake with 32 spokes laced in a three-cross configuration
• Kenda Kontact 58-406 (2.25" nominal) tires
• United 20 x 2.30/2.40" inner tubes.

​​​​



​​​​​






​​​​​​Litepro also offers a 24-spoke ISO406 wheelset. Prioritizing strength and durability, I opted for the 32-spoke variant instead. For a wheel of this size, 32 spokes is indeed quite high. An equivalently built 27.5" (ISO584) wheel, for example, would have 46 spokes. Hopefully a wheel so densely spoked, coupled with my moderate body weight of 71kg and the big, shock-absorbing tires, will result in a long, trouble free life with a reduced chance of spoke breakage.

I ran Kenda Kontact tires on my 16"er folding bike, and they provided flawless service with zero flats riding around town at home and on two tours, including a cross-country tour of South Korea. They are not the hardest wearing nor the lightest tire, but they are no porkers either, roll well with a directional, knurled tread pattern with water clearing swipes and sell for only $4 apiece. Their 58mm width also recommends them to folks who want a wider, cushier tire than can be run at lower pressure for a more plush ride. For the price and what they bring to the table, I can't think of a better value, general purpose tire in the ISO406 size than the Kenda Kontact.
​​
The inner tubes were deliberately chosen to be slightly oversized for the tire so that air retention and puncture resistance are improved however marginally, and so the valve and the surrounding area, the most vulnerable part of the inner tube, is less stressed as a result of decreased deformation.

Wheel height: ~52cm
​

CEBEP

I wish these tires would fit Brompton for a little more suspension.

Ron Damon

You've got a full-sus Birdy that can take 50-355 Big Apples. Why are we even talking about Brompton? 😉

CEBEP

Because I already have Big Apples on Birdy but I also have Brompton and a little more suspension wouldn’t hurt

Hrodwolf

Building your own bike should be an interesting experience.
Please start your Storm project and document it!

Ron Damon

The 58-406 nominal Kenda Kontact clears the frame front and back with room to spare. At the fork there is still about a 1.5cm gap between the tire tread and the fork crown, and about 1cm gap between the tire sidewall and fork legs, leaving room still for fenders/mudguards.



The rear is more of a mixed bag as top clearance with the chain- and seat-stay bridges is very ample at about 2.5cm. Lateral clearance with the chain-stay, however, is a lot more constrained at about 0.5cm.



The reason for the generous tire clearance on these framesets is that they are designed to be built with either ISO406- and ISO451-size wheels so clearance for the former wheel size is ample.

Schwinnsta

The problem I have is that I need fenders for the riding I do in my location. About the largest I can do is 2 1/8 in the front and 2 in the rear on both the Swift and Zizzo.

CEBEP: 1 1/2 X 349 will fit on the Brompton without fenders. I make do with the Contis + fenders.

Ron Damon

To complete the wheels, I installed Shimano SLX RT66, six-bolt 160mm rotors in the front and rear, and a Shimano Deore M4100, 10-speed 11-46T cogset.

The rotors are the lowest-priced Shimano part compatible with both resin and metal brake pads, and were chosen for that reason.

​​​The cogset is all steel, making it heavier than cogsets with aluminum sprokets, but also a lot harder wearing and longer lasting, in line with the general ethos of the build. It also has a large gap, 37 - 46T, between the two largest sprockets. Whether this is objectionable in actual use remains to be seen, but given the range of 418% and the $34 price for this part made in-country, it's hard to pass up.


​​​​​


​​​​​







Note the use of Torx bolts to affix the rotors





Cost of the complete wheel pair: $160

Hrodwolf

I must say that I'm tempted to build the same bike as you to understand the process and have a folding bike with such tires!
The two Shimano parts cost here €95.

Reddleman

There’s a 37-46T gap on the 9-speed cassette on my setup, I can’t say I’ve found it a problem in reality. It’s a step down but not a jump down when you need it.

Now, hurry up and tell us what derailleur are you proposing to use with your 10-speed setup and show us what’s the ground clearance like 😛

Ron Damon

Kia ora, thanks for asking. The RD will be the same part that I've used since 2018 on my other ISO406 wheel folder, the Shimano Deore RD-M6000-GS medium-cage RD which in practice can span 46T without issue.


Consequently, ground clearance will be even less of a concern with these even taller wheels. So, how do like them apples? 😛😛


Shimano Deore RD-M6000-10 GS (medium-cage), 53-406 tire

This versatile Shimano 10-speed part capable of spanning a 46T cog is becoming more difficult to source as the industry moves inexorably towards an ever increasing number of speeds. Now, while they are still around and their price has dropped, is a good time to pick one up.
​​​​

Hrodwolf

I'm tempted though I lack the know-how.
The Litepro wheels with 32 spokes are not available on the store. With shipping and VAT, that will be more expensive. I don't think there are alternatives available in Europe.

Ron Damon

Front - 1.75kg





Rear - 2.4kg




​​​​

Ron Damon

With the wheels now complete, I moved on to the two other main turning axles of a bicycle, the headset which allows for turning of the handlebar and change of direction, and the bottom bracket that enables pedaling and propelling the bike.

The installation of the headset is likely there most involved process of building the bike. It's actually four separate parts that need to be installed: upper and lower cup, upper and lower bearing cartridge. For this, a press-fit tool is required.


Removable, stand-alone bearing cartridges shown bottom center inside their respective cups. Fork washers shown top left and top right. Top center is the crown that fits flush against the handlepost.




A bit of a gamble, the Meroca BB is a concession to aesthetics. 🤞🏼 Fortunately replacing Hollowtech II BB is quite straightforward and the BB shell is the ubiquitous BSA 68mm standard found most everywhere should it need replacing.
​​​​​​​

Hollowtech II bottom bracket which simply screws on. BB wrench needed to tighten.
​​​

ipostnak3d

hi there.

does anypone know what colors to mix to get this look on a alloy frame?

i would love to paint my fnhon blast frame!

thanks in advance!

ipostnak3d

how do i paint a polished alloy bike frame to look TITANIUM COLOR? does anyone know which colors to mix pleaseeeeeeeeeee??? thanks in advance!

Ron Damon

​​​​​​

Ron Damon

This build is still a work in progress, but I finished a minivelo build based on a 46T low cogset, the same Shimano Deore M6000-GS RD and tires, and posted a proper, transparent image of the minimum ground clearance. The thread is here.