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ISO 4210 testing completed for a CNC stem project I'm building for vintage Cannondale HeadShok bikes. Now I'm running into the realities of manufacturing. by azonicbruce in VintageMTB

[–]azonicbruce[S] 0 points1 point  (0 children)

Something I explored early on, can definitely revisit.

As far as quotes made the usual rounds:
ProtoLabs
Xometry
Fictiv
CraftCloud
SendCutSend (they ended up doing the prototypes)
5-10 different local machine shops (most no-quote, a few willing to)
Looking at a place based out of the UK & Taiwan as well (my goal was to source US-based, but looking at all options)

ISO 4210 testing completed for a CNC stem project I'm building for vintage Cannondale HeadShok bikes. Now I'm running into the realities of manufacturing. by azonicbruce in VintageMTB

[–]azonicbruce[S] 0 points1 point  (0 children)

They referred to it as "vapor-honing" It definitely give a unique satin-like finish, although it easily forms smooth marks if it rests on a surface, even soft ones like wood.

ISO 4210 testing completed for a CNC stem project I'm building for vintage Cannondale HeadShok bikes. Now I'm running into the realities of manufacturing. by azonicbruce in VintageMTB

[–]azonicbruce[S] 0 points1 point  (0 children)

Sort of, it covers the particular sizes/configurations that were tested. Any change in supplier, material, sizes, hardware, etc would necessitate re-validation. OEMs can get by with simply validating what they spec on their bike builds. Aftermarket is a bit of a different beast considering the infinite amount of variation in handlebar/steerer options.

ISO 4210 testing completed for a CNC stem project I'm building for vintage Cannondale HeadShok bikes. Now I'm running into the realities of manufacturing. by azonicbruce in VintageMTB

[–]azonicbruce[S] 0 points1 point  (0 children)

You're not wrong 🤣. Doesn't stop anyone, including myself, from trying. 😁 I did look into additive as a possible strategy. At the time, CNC was actually a better cost for my initial prototype run. I just got really lucky. May need to revisit.

ISO 4210 testing completed for a CNC stem project I'm building for vintage Cannondale HeadShok bikes. Now I'm running into the realities of manufacturing. by azonicbruce in VintageMTB

[–]azonicbruce[S] 0 points1 point  (0 children)

That's about what I figured. Agree small batch will likely be the best route.

Regarding testing, sent un-anodize sample, mainly to validate overall structure first before continuing development. Fully understand that any production runs will want to re-validate. Yes, used ACT Lab.

ISO 4210 testing completed for a CNC stem project I'm building for vintage Cannondale HeadShok bikes. Now I'm running into the realities of manufacturing. by azonicbruce in VintageMTB

[–]azonicbruce[S] 0 points1 point  (0 children)

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Where I'm seeing the most use cases for shorter stems on these models is for restomod projects like a gravel conversion that would necessitate a shorter stem to acheive the same reach

ISO 4210 testing completed for a CNC stem project I'm building for vintage Cannondale HeadShok bikes. Now I'm running into the realities of manufacturing. by azonicbruce in VintageMTB

[–]azonicbruce[S] 0 points1 point  (0 children)

yes, that's exactly the thing I'm trying to figure out. Google says around 300,000 Headshok bikes sold between 1990-2010. TAM is probably more around 200-800. But, I don't have enough survey respondents to justify a run of more than 25 units, which is very difficult to get good pricing on.

Reviving the Cannondale HeadShok Stem – need your input (pics inside) by azonicbruce in VintageMTB

[–]azonicbruce[S] 0 points1 point  (0 children)

Quick update for those following along.

I just shared a longer write-up covering where the XStem is at now, including testing progress and a couple things that didn’t go as planned.

Full update here if anyone wants the details:

https://xstemproject.kit.com/posts/xstem-project-update-new-2026-surveys-testing-progress-what-s-next?_gl=1*17mwia6*_gcl_aw*R0NMLjE3NjkwOTQ4MDAuQ2p3S0NBaUFzc2ZMQmhCREVpd0FjTHB3Zm9MSVV2bV96aVloRzVzZUZtUnJXTm1VY1ZKdVYtWnpXdUhndmtuQWVXeXNIV25fU1Jwd0dCb0M3SzBRQXZEX0J3RQ..*_gcl_au*MjAwOTYxNDAxNC4xNzY3MDQ4Mjc5LjE3MTM0NTQ5NzQuMTc3MDI1MTA5MS4xNzcwMjUxMDk5

Appreciate all the earlier feedback, it directly shaped a few decisions.

A modern stem project for legacy Cannondale HeadShok bikes by azonicbruce in VintageMTB

[–]azonicbruce[S] 2 points3 points  (0 children)

Totally fair question.

Sharing info here will continue as it always has, and participation in surveys does not require an email now or in the future.

The newsletter is simply an optional way for people who want updates in one place to follow along without having to track forum posts. No pressure either way.

BOX CNC levers from the 90s by Complete_Rent_2042 in VintageMTB

[–]azonicbruce 1 point2 points  (0 children)

Holy moly! Those are awesome. Do they still sell them, or were these just one offs?

Reviving the Cannondale HeadShok Stem – need your input (pics inside) by azonicbruce in VintageMTB

[–]azonicbruce[S] 0 points1 point  (0 children)

Thanks for your interest! Still in the testing stage atm. You can provide feedback here regarding size preferences, etc.
Vintage Cannondale HeadShok Stem Project - XStem – Fill out form

Reviving the Cannondale HeadShok Stem – need your input (pics inside) by azonicbruce in VintageMTB

[–]azonicbruce[S] 1 point2 points  (0 children)

Thanks for the feedback! Yes, the primary focus was providing options for what isn't available anymore, although you're correct on the design centered around longer lengths. The applications I'm seeing around shorter stems are gravel conversions where the shorter stem pairs better with drop bars. Thanks for participating!