I finished my wife's SS Pug build today and promptly folded the front fork under hard braking. (Burnishing the brakes and testing for wheel flex under braking.)
I Googled for bent Pugsley forks to see if there is a known problem and came up dry.
The fork has 100mm dropout spacing with the holes for Anything Cages and no cantilever bosses. It folded right at the top of the brake mount/brace and a wrinkle extends to the edge of the bottom Anything Cage hole.
It is unfortunately not clear to me that this is a manufacturing defect rather than a design defect and I'm a little afraid to replace the broken fork with one just like it. I can't help but wonder if a weakness was introduced with that bottom hole so close to the brake brace. It's pretty disconcerting to have folded the fork so easily.
PS. I've never seen a bent fork that wasn't caused by an accident, usually bike vs. car. Have you?
It's good to know about this stuff. And I applaud everybody for their civil manners!
I've got an enabler fork on the way and I will definitely be putting it through some "testing" prior to my first trip to the trail.
A friend that owns a local shop bent his Karate Monkey fork in much the same way as the OP. I think he just called it a wash and ordered a replacement.
Hi I'm new to the forums.I'm a machinist and pro gunsmith and know allot about metallurgy and heat treatment. After a part is hardened it is tempered or drawn to soften it to the necessary hardness to meet spec's and remove brittleness.After welding or hydro-forming the parts are often stress relieved to prevent cracking or twisting & warpage while this is a heat treatment is dose nothing to harden the material it may in fact remove unwanted hardness.A part can be tested with a triangle file if the teeth of the file skip off the surface it has been hardened.The dropouts may be hard and the forks unhardened.I hope your problem is fixed soon.
I tried to order a 100mm fork from both Treefort and Fatbikes.com for a generator hub Pugsley I'm thinking of building up; both sites had showed them in stock when I ordered. Treefort said the fork has been discontinued and they have no more stock, and Fat bikes said it's been recalled and Surly is working on a new one. I emailed them back to see if there were more details, but haven't heard anything.
A couple days ago I called Surly up and spoke to one of the crew about the 100mm Pugs fork. Discontinued; no further information available. I would really love to get hold of something that could accommodate an Endomorph if needed yet allow me to run a 100mm dyno hub up front.
Searching for a closeout Pugsley fork led me down a rabbit hole which ended at Vicious Cycles. Does anyone have experience with their Snow fork? Looks like I may end up going that route if all else fails.
Odd story, especially the STFU part of it...
If it actually has been recalled, I hope Surly will make a statement ... Surly?
I'm just building up a new wheel for the 100mm pugsley fork I bought new not so long ago... am I risking my pristine smile by riding one?
That's cool bugshield. I'm not making any assumptions nor bashing anyone/-thing, it's best to wait for what the pros say anyway.
I'll stick around until then.
Yeah, and having completely forgotten about this thread, I raced Triple D on one of these forks a couple of weeks ago. Held up fine. My body, on the other hand...
Fing surly.. They never replied to one of my emails regarding a new sulry bike i got... Granted, it was not nearly as severe an issue as the cracks and bends being discussed here..
Everyone says good things abt surly, but i've only experienced the opposite... Shady... Next bike will not be a surly
i have a bent one as well.. only i was going into a corner and the damn thing folded on me.. i have a pugsley and a neck romancer... i was on the standard pugs when it happened.. my gf was on the neck romancer.. my pugs has the red offset fork.. neck romancer has the moonlander.. that will be getting checked asap to make sure it is.. so now we know of two for sure.. only i did suffer a few minor injures.. some pretty big bruises on my upper leg and nice one on my shin.. first i thought i might have busted my leg. dont know what part of the bike i hit with it.. but its a deep ass bruise.. and bounced my head off the dirt.. thankfully i was wearing a helmet... so other than a few small scrapes and cuts, and a few gnarly bruises and a sore neck i made out ok.. coulda been worse i guess.. wrote the company and email.. shouldnt have quality control problems on a bike that costs what it does... brake was rubbing really bad.. wasnt rideable.. we were 10 miles from civilization deep in the woods.. so me and a buddy of mine popped the front wheel off.. and had to actually put our weight on it to bend it back so it would be rideable to some degree.. kinda a bummer on a $1800.00 bike that really doesnt have much special stuff on it other than fat tires.. i was looking at getting a surly karate monkey.. cause i was in love with my surly's until now... wanted to go with their 29er single speed cause of all the things you can do with them.. but might have to go another route now.. they brag about their parts being made in taiwan because of the quality taiwan produces.. hmm.. somebody over their seemed to miss the mark.. i talked to a guy at surly the other day and supposedly the company that builds their forks used the wrong thickness of tubing on that day.. how the hell does somebody just in one day change the diameter of tubing on about 975 forks...
i talked to a guy at surly the other day and supposedly the company that builds their forks used the wrong thickness of tubing on that day.. how the hell does somebody just in one day change the diameter of tubing on about 975 forks...
I weighed my uncut fork at 1150 grams and expected it to weigh 1168. I would think that thicker tubing would be a difference of more than 18 grams but what do I know?
I do have some pictures but doesnt look as severe as yours.. it wasnt anyways.. but now its not because I had to bend it back ad much as I could to ride it out of the woods.. I dont wanna post pictures yet.. I dont think surly sucks by any means and dont want anyone to think that.. just frustrating that it happened.. I know stuff happebs and sometimes stuff just gets missed or whatever.. were all human.. but definently need to get word out to the people with the bad forks so nobody gets hurt in a bad way.. can u post a pic of the fork u went to?
Talked to matt moore at quality bike products today.. he assured me the new forks were good to go.. they recognized whatever the issue was and it was corrected.. I feel confident after talking with him that all of us fat bikers surly and salsa riders are good to go.. I mentioned maybe putting the word out on some forums and what not just so those bikers that maybe dont go to their dealers for every repair can hear about the fork recall.. I still love my bike.. was frustrated at first bit they were on the ball and contacted me asap.. I didnt wanna ride either of my fatbikes until I had a better understanding of the situation.. I feel confident my new fork will handle just about anything I throw at it! He told me they did the new testing and they passed! Thanks surly and riders get your forks checked out.. and hopefully I see you all out on the trail!! Ride on!
my LBS claims that my bike wasn't one affected by the recall, yet I noticed today that the powdercoat is cracked above the disc mounts. Anyone have any advice?
Contact Surly. You could have a fork that needs to be replaced and one that is not part of the recall. I wouldn't take any chances with my front wheel/fork - the consequences of a failure are too gnarly.
Took it into Bicycle Revolutions, my trusted Surly Dealer in Philly. One of the mechs looked at the cracked powder coat on the front of the fork above the disc mount and thought that it did look like a valid warranty item. I'm bringing it back in on thursday for the shop owner to take a look at and begin the warranty process. I'm not looking forward to having the bike out of commission for a week or more and a little disappointed that the replacement fork won't match, but that's the way of it, I guess.
I had both of my forks (100mm non-offset & 135mm offset) replaced and for the offset one I got the same replacement, but that was a couple of months ago... maybe they ran out?
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