Building Jon’s Adventure Road Bike

I thought I’d share some of the details of an interesting bike I just had the pleasure to build. It’s for a tall guy, tall enough that I was getting up to the some of the limits of available tubing and approaching the top of the range of some of my frame fixture adjustments. Seven feet is a lot of rider. That’s a lot of leverage and power to put into the bike, so in designing the bike we scaled things up. We used an Enve Gravel Road Disc brake fork, as it has a long steerer with larger diameter than a standard road fork. It also has room for larger tires for a larger rider. Thru axles are a more robust connection of wheel and chassis and the disc brakes give more stopping power and modulation.


Here are the tubes partially prepped.

The seatstays are up top. I put a custom S bend in them, as with almost all the bikes, to manage tire clearance and add some subtle curves to the bike to look sexy. These are a larger diameter stay with more wall thickness than I normally use on road bikes. Later they get mitered and I used pretty much the full length.

Below that is the top tube,  a larger diameter (34.9mm OD). I was fortunate to find this one in my stash. It’s made from a True Temper OX Platinum/S3 alloy but in a little greater wall thickness than the lightweight material, it would normally be used as a down tube. It has a subtle bi-oval shaping, which works out well for mating to the large head tube and the smaller diameter seat tube.

The seat tube is the next tube down from the top. It’s one of the few remaining specialty seat tubes from True Temper. I used every bit of the length. It’s a great one for this bike as the diameter is larger than the seat tubes I normally use, it has a little more wall thickness and is triple butted with a nice external butt up top to reinforce the area that sees joining of seat tube, top tube and seat stays, as well as reaming and slotting to take the seat post. The down tube is a large 42mm diameter, and has a nice aero, tear-drop shape that I ovalized in the opposing direction at the bottom bracket to better resist pedaling loads there. You can see some of the shaping in the lower pictures. Below that are the chainstays, a tandem chainstay, that I dimpled for tire clearance and joined to stainless steel Paragon Thru axle dropouts and a flat mount disc brake mount.


Whoa, that’s a lot of head tube. File for reference. I machined the outside center section down a little bit to shave some weight of this big tube.

Here you can get another view of the tubes and a sense of the shaping of the down tube.

After mitering, cleaning, tacking, checking alignment, welding and more alignment checks, we have the front triangle and chainstays done.

Seat tube/top tube junction

Down tube/ Head tube junction. With the photo so close up you can see the change in thickness of the head tube from where it is full thickness at the end, then the tool marks of the machining operation. I posted a quick video clip on Instagram (@caletticycles) of machining down a head tube recently, so you can take a look to see that process in action.

The completed frame after the seatstays, bridges, cable guides and bottle bosses go on.


You can see how long the seatstays are – there is plenty of room for a 32mm + tire, but it doesn’t look that wide due to the proportion. The amount of space above the seatstay bridge gives a bit of perspective of the length.

It was a fun project to design and build, and I think Jon will really enjoy the ride of this bike. Keep an eye out on Instagram (@caletticycles) and the blog here for pictures of the bike after it get’s back from paint and is built up.

Thanks for reading!

-John Caletti

Scott’s Titanium Road

Jeff’s Titanium Cyclocross

Casey’s Ti MTB

A visit to Paul Component Engineering

I was in Chico last week for “Paul Camp” – a press event to introduce the latest and greatest from Paul Component Engineering, and to do so with the aid of some sweet custom bikes from a selection of builders. I was stoked to be a part of this event. It was great to get to ride and hang out with my bike builder friends, the media folks, as well as the stellar crew at Paul. Paul Comp. is inspiring to me as they’ve been producing some really well made and innovative bike parts at their Chico, CA machine shop since 1989! That’s the year I got my first real mountain bike and when I started high school! It was great to see the stoke of the staff, each one moving the ship forward, creating great bike parts we enjoy on our rides.

Machine operators Patrick and Briana, with Brett peeking through from the background. Before lunch, Patrick was running the lathe, Brett was cutting stock on the band saw and Brianna was making parts on the CNC milling machine.

Here are a few photos of the shop. You can find more details on the parts, bikes, and rides as the media write it up. In attendance were Bikerumor, Bicycling, Cyclocross Magazine, All Hail The Black Market,, Gear Patrol, Gear Junkie, Bicycle Quarterly, and Dirt Rag. The big news is BLUE! It’s their new, limited edition color that replaces purple and will be around for about a year. For those of you planning your next dreamy bike, you can bling it up with some Blue “set and forget” thru axles, a “Boxcar” stem, a “tall and handsome” seatpost, and if you’d like the best cable actuated brake you can get they make the “Klamper.” There are several other widgets as well. Check out for more.

Paul “Klamper” cable actuated disc brake

Paul’s workshop with an amazing selection of manual machines that he uses for prototyping new products.

Selection of radius cutters 

Various cutting tools, including drills, rouging cutters, 3 flute straight cutters, and a 6 flute ball end mill in the foreground.

Paul holds the finished crank arm above the block of aluminum stock they start with

CNC control panel


From design drawing (above) to finished parts (below)

Quick release parts 

Vibratory tumbler: after machining parts go into the tumbler for deburring and polishing. They have a small room devoted to these operations with various tumblers and different types of media for demurring and polishing. 


Shiny hubs on the shelf, ready for bearings to be pressed in

Shelves and shelves of parts

Titanium Monster Cross bike I made for the event with 27.5 x 2.2″ tires. Sram 1x drivetrain with White Industries cranks, BB, headset (prototype, to be released this fall), hubs, Paul Tall and Handsome seatpost, Quick release seat collar, Disc brakes, Boxcar stem with light/accessory mount, and Paul’s innovative Thru Axles.

Video: Riding to Yosemite

Ride: Kitty Krusher!

Kitty Krusher Route on Strava

Last year while huffing up a climb on the “Ball Mauler” ride, we brainstormed up a “sister” ride and this year it’s happening! The “Kitty Krusher” ride is June 10th! It’s about 69 miles and climbs around 6900′, going up and over the Santa Cruz mountains and back again. It is not an official or “organized” ride.  It is unsupported—a ride-your-own-adventure type of thing. Just show up and pedal. Bring a friend or two and join the fun. We hope to get lots of ladies out on the ride to explore some special climbs. Dudes are welcome too.

Click here to RSVP on the facebook event.

  • Saturday June 10, 2017, 9:00 AM departure
  • Starts at Caletti Cycles World Headquarters – 104 High Road (not High Street), Santa Cruz, CA 95060
  • There’s plenty of parking in front of the workshop for people driving to the start
  • Self-supported : bring a map/directions, food, water, etc. (refuel in Saratoga or Los Gatos – we’ll ride right through downtown)
  • We’ll have a few hard copies of the route if you need one.
  • We aim to roll out together, but some riders will get frisky and we expect the ride to separate into smaller groups as we go.
  • Downtown Los Gatos is a good spot to stop for snacks and drinks, and maybe regroup a bit before we climb back over the hill
  • It’s a road ride, with a little bit of smooth dirt. Road bikes are a fine tool for this adventure (or Adventure Road or Cross bikes)
  • It will likely be H O T on the second big climb up Montevina Road.
  • The descent off that mountain is technical and treacherous! Use some caution, don’t crash now; save yourself for enjoying an Affogato in Los Gatos.
  • Bear Creek is a treacherous descent at the top.. caution advised there too
  • We’ll have the HQ open for some libations, light snacks and workshop tours after the ride.
  • There are many options in the neighborhood for refueling after the ride. Top picks: New Leaf grocery store, Verve Coffee, Companion Bakeshop, Santa Cruz Mountain Brewery, Humble Sea (beer and a little food), La Cabana taqueria, Kelly’s Bakery and Cafe (sandwiches, etc.)

(Shorter Option: After the first major climb, up Mountain Charlie Rd, you can cut out the next 2 climbs by riding South on Summit Road to rejoin the route and descend Soquel-San Jose Road back towards Santa Cruz.)

Ride hard, have fun, be safe, enjoy your new friends, eat well…. 


Kitty Krusher pre-ride on Strava

See a “flyover” of the route on HERE

Ride with GPS route here

Elliott’s 1×11 SCRAMBLER

Fabian’s Ti Adventure Road

Titanium 1×1 SCRAMBLER