ISPs, or integrated seat posts, are one of the more polarizing elements of modern bicycle design. Some adore them, others loathe and despise their very existence. They present a sleek, custom aesthetic to frames while providing a distinct ride-feel, but they also have some challenges associated with their design. Taller riders with larger frames may find transport to be incredibly difficult due to the non-removable nature of the seatpost, and fitting a non-custom frame to riders can also be difficult. The latter being the case here, so
one of our customers approached us due to fit difficulty with their frame. Basically, they were having terrible knee problems as a result of sitting far back on their frame and they wanted to alleviate the problem by moving the saddle more forward. The bike is a production Wilier with a proprietary ISP tube shape, requiring OEM seat-toppers provided by the company. So how does one move more forward on the bike when no publicly available zero-offset toppers exist? Well, that’s where we came in.
We first had to 3D scan the post itself in order to attain the dimensions of the tube shape. When we gathered all that data we were then able to use our handy 3D printer to produce a mold representing the internal dimensions of the Wilier’s ISP. As you can see in the photo above, we replicated the design and also created a small carbon fiber tube to sit atop the mold which would eventually hold the seat-clamp mechanism. We applied a vinyl polymer solution to the mold so we could easily remove the carbon fiber layup after it went through casting and heat compression.
After casting we removed the carbon seat-topper and began the intensive finishing process. Small parts require immense attention to detail, and since this is a one-off part there was no margin for error. We wet-sanded the topper to perfection and finally were able to send it over for a few rounds of clear-coating.
Finally, we were able to reinstall the actual seat-clamp mechanism and finish the project. What we have is a one-off, completely customized zero-offset seatmast topper. It took incredible planning and flawless execution to produce and that’s what you get when you work with Ruckus. Have a problem needing custom solutions that may not yet exist? Call Ruckus so we can provide you better service through science.