Convert an old bike into a new cycle touring bike...

The touring bike I use today started its life as a hardtail mountain bike. A Cube Reaction Race Edition to be precise.  A mid-range aluminium frame mountain bike that cost me around £1500 at the time. It came with all the usual parts; suspension front forks, hydraulic brakes, typical MTB gearing (triple ring - lots of gears), knobbly tyres, etc...  And over the years, I had replaced or serviced just about every part to keep it running in tip-top condition. The photo below is from after completing the Brecon Beast endurance MTB race in Wales. I have awesome memories of cycling through the Welsh countryside, which is probably why I love cycle touring so much. The bicycle has given me many memories, so I wanted to convert it. 

When starting out in cycle touring, I had dreams of bespoke, hand-built, Rohloff geared equipped touring bikes, but I simply didn't have the money to afford these costly machines. I had to make do with what I had in my garage and a small budget to get the essentials. I took a good look at my mountain bike. It was comfortable. I knew it could handle a rear rack (support holes already in the frame). It was a little cranky after many years of hard use, but it had always been a pleasure and very comfortable to ride. This is a really important point if you are about to embark on a similar project; make sure the mountain bike is comfortable for YOU before starting. The nature of bicycle touring is to spend many hours on a bicycle. 

I made the decision to make the changes and upgrades to the bicycle over a few months. I was just getting into touring and thought it would be best to make sure you enjoy things before investing hard-earned cash.

Stage 1

With the bicycle still riding pretty well, despite having a few niggles, I knew I had a good foundation to build on, with a solid frame. To get started with specific equipment for touring, I purchased a second-hand Tarbus rack off Ebay, so I could strap my tent and sleeping bag to the bike. I didn't need anything more at this stage. If I wanted to progress to paniers, I had the option.  For now, my clothes and other items of kit went in a rucksack. With my first few tours only lasting a couple of days, this setup was perfect, apart from the sweaty back from my rucksack! 

Stage 2

After a few weekends away and some local cycling, it was clear some of niggles meant a few parts in need of replacement. Sadly the hydraulic brakes were starting to fail, and unfortunately, it wasn't just a pad change.  I needed something reliable and easy to fix on the road, so I switched to some Shimano rim brakes.  The forks also needed a service, so I replaced these with non-suspension Surly forks to take away the extra weight of suspension and to be able to mount the rim brakes.

The Checklist

Frame: Good condition

Chainset: The Shimano chain-set had been replaced 12 months prior and was still in very good condition. The gearing is perfect for touring, with the triple ring and great selection of gear ratios. My SPD pedals stayed attached too.

Brakes: The original Formula Oro hydraulic brakes were pretty much end of life, and had been used and abused over the past 5 years. I found a good deal on Shimano XT Rim Brakes, so I ordered levers, brakes and cables. My frame and new forks had the brazers for the brakes to screw into, so no issues there. 

The switch to rim brakes was a simple one for me to make. Less maintenance and cost - disk brakes can be a pain to fix at home, let alone when out on tour. And the cost of a new set of disc brakes isn't cheap in comparison. You do lose some braking power, but I'm no longer going down mountains in Wales, so I felt I could live with that decision. And to be completely honest, I haven't missed them. The Shimano XT rim brakes I installed are pretty awesome too! They have performed fantastically in all weather conditions.

Wheels: They had seen better days and were designed for disc brakes. Ordered a new set of hand-built rim brake wheels from Merlin Cycles. A recommendation sent me in their direction. Mavic rims and the awesome Hope hubs to go with them. So smooth to ride and take the excess weight perfectly.  They will last for years to come.

Handlebars: These were standard flat bar MTB handlebars. Always comfortable and a good fit for my body. The only change I made was to add a set of Ergonomic grips. I always suffered from wrist pain, so these looked like a great choice.  They have not disappointed.

Forks: The Rockshox forks were old and had already been serviced a couple of times. They were pretty knackered! I felt I didn't need suspension forks for touring. The extra weight wasn't worth the slightly improved comfort if I ever did go off-road. I decided to do a switch for a set of Surly forks. These simple forks are perfect for cycle touring - taking every lump and bump in their stride and lighter than the suspension forks. 

If you have never fitted forks before, there are plenty of Youtube videos with advice. As with any bicycle mechanics, if you are not confident in your abilities, do take advice, or use a local bicycle mechanic.

Touring Accessories & Other Minor Bits:

• Tubus Rack was already in place from my early tours. Still doing me proud to this day 
• Ergonomic grips onto the bars: wouldn't live without these now. Now looking to add some bar ends to extra comfort.
• SKS mudguards to keep me dry: they came with rubbish instructions, however a fantastic product once you master how to fit them!
• Brooks leather saddle: I had always been intrigued by these saddles and the reports of how comfortable they are, despite looking like they will hurt!  Pleased to report that once broken in, these saddles live up to the great reviews.
• Tyres were switched to Schwalbe Marathon tyres. They have already done a few thousand miles, and dare I say it - no punctures!

The Ride

I have been so impressed with this bike and how it has performed over the past few years! Smooth ride, no annoying noises, reliable and the new components are working well.  I did find I needed to invest in panniers - using a rucksack eventually drove me crazy and I invested in some Ortlieb panniers.

Who did all the work?

I did it all myself.  Over the years I have collected many bicycle tools and I'm fairly confident with bike mechanics.  Anything I'm unsure of I use YouTube. Most of the work I completed was simple swap outs. The brakes and forks were probably the most challenging part to get right. Sawing the forks to the right length was something I had to measure multiple times.

My advice is to be realistic. Is the bicycle worth saving - i.e. is the majority of the bicycle salvageable?  You need a good starting point to stop it from becoming a money pit.  

Start with a clean bike. Take your time and investigate anything you are unsure of. You can always use the local bike shop or friends who know what they are doing for areas you are not confident with. Cycle Touring can involve long distances and be miles away from help. Make sure your bicycle is safe and you can get yourself out of trouble.

It was a good decision to complete this project and I would encourage others to do the same if you have an old mountain bike or similar hiding in the shed.  Get it out and see what could be possible. Recycling what you already have to make something truly great!

I hope this post has got you thinking.  Don't let having the best bike prevent you from touring.  Whether you save an old bike from your garage, eBay, or local car boot/garage sale, cycle touring doesn't have to cost lots of money, and is possible on any bicycle.

My Beautiful Touring Bike

Hope you enjoyed this post and now have some fresh ideas for your bike conversion.

Happy cycling!