Building probably the last size large Surly Pugsley 2.0 that was sold in Europe up to a previous 29+ spec...

 

So... end of the era of probably the best Surly frame set they made (in my opinion!) The Surly Pugsley 2.0 was the last run of the venerable Pugsley with a few good updates that made it better...

Non dropped top tube with seat stay brace removed -yet it has increased stand over to previous Pugs

Frame triangle allows a big frame bag for bike packing

142mm rear hub width allowing full 5" (4.8") tyres on biggest available 100mm rims (basically Surly Moonlander wheels)

Rear hub 135mm reducer spacers included along with 142 through axle so quick release 135mm or 8mm Shimano Alfine internal gear hubs can be used

Reversible wheels allowing single speed options and removal of broken rear mechs in an emergency

29+  (29" x 3" tyres) 27.5 Fat, 4.5" Fat, 4.8" Fat - takes every available wheel and tyre size combination 

When 29+ the BB height is only raised 10 -15mm (25mm on older Pugsleys as they were designed around lower tyre wall 3.8' (4") tyres, the Pugsley 2.0 compete bikes have 4.4" tyres same height at 4.8" tyres...

Enough of all those great things, basically you get Moonlander wheels whilst still on a 100mm threaded BB allowing cheap cranks along with 1 1/8th headset for a cheaper bike build...

Sadly they dropped offset rims also, they really should have just made tubeless ready Rabbit hole rims and it would be job done, two bikes in one - but I guess Surly don't want you to just buy one bike nowadays, 

Sadly I think the Surly of old and the guys who were there back when some amazing ideas were thought up have moved on , and they just seem interested  in what most other companies do...

With about a dozen 27.5 and 29er frame designs its all went a bit too mainstream...

Anyway G and I have all that we need plus loads of spares for future years of cycling... 

So as you know i already have a size large Pugsley 2.0 and G has a size medium Pug 2.0 we run on full 5" tyres using Moonlander forks on the beaches.  However when I read production was stopped on the Pugsley 2.0 weirdly just after one production run I searched for a spare replacement about a year and a half ago having paid off my mortgage and paying the full whack (approx £700) I found a shop in Italy with one size large left in stock and it arrived here in bonnie Scotland a week later... I was not going to pass on the chance of another It went into the loft with the plan to keep as a spare, but, the bikes are just too nice to not use and with my Surly Wednesday going back to MTB duties with suss forks and dropper seat post and 29+ with tyres ideal for soft trails,  I have decided to again build a Pugsley 2.0 in 29+ to use bike packing as it is just such a great bike to ride. I am going to build it more or less like I built the first Orange frame set as I have all the parts sitting like those retro style Nitto Moose bars, 10 speed group set with retro thumb shifter, old square taper Shimano XT cranks etc... and the Surly Rabbit hole offset reversible wheels are sitting unused and ready to bolt on, here is a pic of the first Pugsley 2.0 frame set built up as a bike 29+...

So this week I got the spare frame down from the loft and unwrapped it. I`m keeping the fork it came with as I already have the fork from the other with uncut steerer tube...

Prepping this frame has already been featured in the Saltwater Exposure to Fatbikes blogpost I recently updated with the Army Green Pugsley and Lanoguard treatment, but here are a few more pictures before the treatment spray.  As I do with all new frames that do not already have a Bottom bracket drain hole I drilled tone using a 6mm drill bit.  I know your saying I have now voided my warranty doing this... but, through experience of Surly frames I can safely bet nothing will go wrong with this frame in the time it's under warranty, anyways there are no others being made to do warranty replacements!...

While the frame was still clean and dry I added white decals as I think they look so much better. Going through my Stickers I have the one white set left with the Pugsley decal, doubt there will be any more available, but it's the last build so may as well use them...

I applied them straight on top of the black decals, they went on separating from the top sheet a lot easier being inside and warm...

Back out to the shed and I hung the frame  and gave the stickers a quick over spray with clear lacquer  to make the stickers last a bit longer as they chip and peel of easily...

New Surly frames of the last few years come with the internal frame tubes ED coated, you can see the finish here inside the bottom bracket shell,

and although this bike will mostly have 29+ wheels fitted and not be on the beach it  will prob no doubt at some time get some fat wheels fitted so I was going to go the full Saltwater exposure treatment on the frame set...

Next was all the Allen bolts on the frame and forks were removed and threads greased with the Lanoguard Moto grease...

Then using the holes at the junction of the bottom bracket and headset I used the Lanoguard hand sprayer with Wand to spray some inside the tubes...

Here is a film using the Lanoguard Hand sprayer and Wand attachment with 360 degree spray pattern...

I added the headset next, a new Hope in shiny silver to complement this build, I greased all surfaces where the bearing sit and cups fit into the head tube before pressing them in...

Again along with the silver hope headset silver headset spacers and the brushed steel Nitto bars...

Another cheap £20 159mm wide axle 100mm square taper bottom bracket was fitted with the Shimano XT crank arms, I need to find a Wolftooth Stainless steel 30t narrow wide chainring but none in UK this now, so fitted a cheap alloy one...

46t Sunrise cassette with Shimano XT rear mech and my favourite cockpit parts of Microshift thumb shifter and Ergon grips...

The wheels were re juiced with Stans sealant and good to go...

Silver BB7 cable brakes for that simple Pugsley low maintenance - fix in the field maintenance...

And all done...

With chainring moved onto the middle ring of the crank arms the chainring was better for most riding which is about half way to 3/4 way up the gears....

As often with a 1x set up the chain is not to happy to stay on in 1st if back peddling but I can live with that...

Wee film of the build, Song is `Buckie High` by Boards Of Canada

A fine pair of Pugs!...

A quick ride around Tyninghame woods to bed everything in and re tighten the crank bolts etc...

Some film on The Secret Trail...

We film on The secret trail; Song is `Orange Romeda (Unmixed) by Boards Of Canada

All good and it was back to the van and back to the Man Cave and after a quick once over everything to check tight,  it was on with the bike packing gear...

The main frame bag and top tube bag will be left on along with bottle cages for regular local and all day xc rides and front and rear luggage can be added for longer bikepacking trips

Best remove the bottle chain Allen bolts and fit dome head bolts to not wear holes on your frame bag, if you don't have these you could just tape over the holes as you won't see it once theban is on,

This is a Surly No8 size bag that fits the Large Pugsley 2.0 and a Medium Wednesday which it previously was on. These bags are pricy, but bomber with tough zip and I still have a 13 year old Revelate frame bag (previously then called `Epic Designs`) who make the Surly bags, Buy good quality and buy once....

The large size Top Peak bag I bought new for £34 and has a lot of room for phone and snack bars and a separate adjustable separator where I sorted a spare Go Pro battery and last could of years a face mask...

So they both will stay on the bike along with cages, two bottle cages on the forks - these are Blackburn cages as strong and last years.  the larger cage on the down tube will be used for a Nalgene bottle for extra water when away on trips...

I usually carry a bottle in the frame bag but I may have extra clothing on longer day trips so it is always handy to have extra storage for a bottle or two, you do notice the weight though with two 750 ML bottles...

The cage on the down tube I remove the straps when not being used and store them in the the frame bag under tools...

The Alpkit seat rail is a good idea as you don't get any sway on the rear seat bag whatever size you fit, you just have to get used to always stepping through the bike getting on and off to not catch your leg on it...

 

I swapped this one out for another with a rear splash guard I cut up to fit for when there is no bag on...

While at it a front Alpkit mudguard was also added...

I have the smaller black bag ideal for day trips for water proofs etc..

And the larger camp waterproof camo bag for stove and food etc when away multi day rides...

The front mounting system which I use a 25 Litre Alpkit bag will only go on for multi day and overnight trips... fuel pods can also be add-on the bars for more stuff to be carried...

And that's the second Pugsley 2.0 built and rolling - as a  29+ KramPug 2.0...

More soon...