Visit the complete set here: Cannondale DI2 modification
Hypercat Bike Works has been building DI2 specific bikes since Shimano released the group. Master Mechanic Phil is a DI2 certified mechanic and through HBW has been involved with electronic shifting from early Suntour browning systems to Mavic’s Zap and Mektronic groups through the modern era of Shimano DI2, Campy and beyond.
This project was commissioned to take the original externally routed cabling and run all internal. while many bikes are designed at the factory to have DI2 routed through the frame it is possible to modify most frames to accept the internal wiring with the correct choice of wiring harness. for this bike the frame is rather large and a large kit was necessary. Shimano offers many options and with a good amount of pre-planning and measuring the ideal wiring harness can be chosen. Due to the shape of the tubing around the front derailleur and the location of the water bottle mounts it was chosen to use a short battery mount to place on the left chainstay and an external junction box with all other elements routed internal.
For factory spec’d internal frames the Bottom bracket has capacity to route the cables around the main crank spindle. In this case holes needed to be bored through the main BB shell. The first hole was the main access hole from the outside of the frame through the BB shell. The second hole was the front derailleur hole mated to another port hole located at the front derailleur. The final holes bored were the rear derailleur routing through the BB shell and through the right chainstay. To keep the wires from tangling with the crank spindle I used two products: #1 – removed the FSA adapter sleeve and shimano BB and opted for the BB30 shell and Hawk Racing BB30.24 adapters. This improves performance and gets the bearings further out. #2 – added protective sleeve around crank spindle so that no moving parts are in contact with wiring if they should move around.
On the frame grommets were added to exit holes for wiring to maintain water tightness.
Front end controls were routed entirely through handlebars and stem. Main controller mounted to top of stem and all other excess wiring tucked into available tubing. No modifications were made to braking system other than routing cabling through stem.Hypercat Racing is a by-appointment Bike Fit studio and custom build boutique located in Ventura California specializing in aero and skinny tire bikes.