Calfee Cycles SuperClean di2 and EPS electronic wire integration into stem and steerer tube

Calfee’s always been one to integrate as much as possible, and now they’ve taken electronic wiring mods to the next level.

Called SuperClean, it’s a patent pending design that funnels the wires coming from the shifter directly into the stem through small ports. From there, the Junction A box for either Di2 or EPS is mounted to the bottom of the expansion plug, and all wires then run through the steerer tube and into the frame.

Where it gets really tricky is with the indicator light and internal wiring…

Calfee Cycles SuperClean di2 and EPS electronic wire integration into stem and steerer tube

Small ports are molded into the stem’s overwrap of the bar, leaving just enough room to wiggle the wire’s connector end through.

Calfee Cycles SuperClean di2 and EPS electronic wire integration into stem and steerer tube

The wires plug into the Junction A box, which is positioned so its indicator light beams up under the top cap’s bolt.

Calfee Cycles SuperClean di2 and EPS electronic wire integration into stem and steerer tube

The light’s transmitted via fiber optics placed in the core of the bolt.

Calfee Cycles SuperClean di2 and EPS electronic wire integration into stem and steerer tube

The junction box is attached to the expansion wedge, so it all pulls out as a unit for charging. A notch in the top of the steerer tube makes room for a small tab on the cap so it won’t twist during installation. From there, the wire goes into the downtube and on to the battery.

There’s an extra loop of slack in the cable to prevent pulling or pinching, and they’ve done all the strength testing to ensure the holes don’t adversely affect the fork.

Price is $275, which includes labor and components (Junction A, wires, expansion plug). You could drill your own fork out to make it work, but they really don’t recommend that. So, you’d also need their bar/stem combo and their fork.

Calfee Cycles custom bar-stem combo with integrated garmin cycling computer K-edge mount

They’ve also updated their integrated cycling computer mount, extending it a bit to accommodate the Garmin 1000’s larger size. So it’ll fit virtually any cycling computer now.

Calfee Cycles custom bar-stem combo with integrated garmin cycling computer K-edge mount

Earlier iterations used a bolt-on unit, but this is the first completely integrated production version that bonds the mount’s “torpedo” beam onto the stem.

Calfee Cycles custom bar-stem combo with integrated garmin cycling computer K-edge mount

The computer’s mounting base is now modular, letting you bolt in any computer mount you want (or can) drill a hole in. The K-Edge one shown here is a stock unit from that brand.

Calfee’s Michael Moore says it’s likely they’ll make the system a bit more functional soon that adds a second mount to the bottom for things like action cameras, etc. As is, the bar/stem/mount combo is $450 with customer-provided handlebar and stem. Without the mount, it’s $300. If you want paint, that’s another $150. They can laminate any carbon stem to any carbon bar.

Calfee Cycles 3D printed custom frame molds

At the Philly Bike Expo, we learned of Calfee’s plans to 3D print molds, which would let them offer more angles and sizes then their already huge library of metal molds allows. Check out our factory tour for a look at how their frames come together.

Calfee Cycles Manta custom carbon fiber road bike

Those particular molds were created for this bike, which features a very, very tall head tube. They didn’t have standard molds for this size, so their new methods open up possibilities. And while we’re looking at the bikes, let’s check out the amazing paint Calfee offers:

Calfee Cycles Manta custom carbon fiber road bike

Calfee Cycles Manta custom carbon fiber road bike

Calfee Cycles Manta custom carbon fiber road bike

They finally wrapped up production of their branded Lizardskins suspension dust boot for the Manta’s elastomer-based micro suspension.

calfee-cycles-sparkle-paint02

Another bike was on hand with some very sparkly paint!

calfee-cycles-sparkle-paint04

Leh Seats custom embroidered and hand sewn bicycle saddle cover and handlebar tape

On the red and blue one, they contracted with Leh Seats to custom embroider color-matched handlebar tape and saddle. Calfee sent a couple of the tubes to Carson Leh to get the stitch’s colors correct, and the finished product makes the entire bike an incredible one of a kind.

CalfeeDesign.com

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Rico
Rico
6 years ago

That is another super tall bike that could use 32″ wheels. Then everything would be in proportion, look good and ride amazing I bet. The big man who rides it would probably be fast as hell too.

Tony
Tony
6 years ago

Do they have a disc brake fork with support for a 15mm thru-axle? This would be incredible on my Domane 6.9. Would love to completely redo the headset.

smw
smw
6 years ago

Calfee bikes and designs are so 1990’s.. their bikes don’t have that nice flow to them… its like they’ve bolted bits and pieces together to make a bike..

Homburger
Homburger
6 years ago

I have trouble understandung how the DI2 cables go into the frame from there. I mean, you´re in the fork with the routing shown. From this point you´d have to have a hole to get into the frame, right?

b
b
6 years ago

That saddle is amazing

brattercakes
brattercakes
6 years ago

That candy coat paint though…

jeff
jeff
6 years ago

Is that the same Michael Moore from Spokesman Cycles?

Slammed
Slammed
6 years ago

Holy head tube

CJ
CJ
6 years ago

I would assume there is a hole in the steerer. Rob English has been doing this for a while as well. I emailed him about it and he was happy to talk about the details.

I owned one of Calfee’s early seat post batteries for Di2 and it worked great. I am not sure I would buy their bar/stem combos, but I have to give them credit for what they are doing with Di2 and EPS. It is cool to see small companies thinking outside the box and customizing things. Keep up the good work.

Mick
Mick
6 years ago

@Rico…as soon as you build some high performance wheels & sew up some equally good tires, I’m sure he would…’til then The discussion is moot until the industry comes up with performance offerings…Then, I assume, we can direct all the bitching & moaning about a new standard to your desk(?)

tom
tom
6 years ago

I don’t want anyone with that computer mount riding in a pace line with me…thing might as well be a harpoon.

J
J
6 years ago

I don’t have my own Di2 so I don’t know how often you’ll need access to the junction box button, but I have seen a rear der wire get detached during a group ride. This was very quickly reattached, but to get the system shifting again the junction box button had to be held for some length of time. How does the internal stem allow for that? Do you need to take the top cap off?

'Merika
'Merika
6 years ago

Is there a recumbent version?

Jason
Jason
6 years ago

@Homburger

I also am curious about this. Even with a small hole in the steerer it seems like the wire would be twisted, pinched or severed. Maybe there is enough space in the headtube to also allow the wire to wrap slightly around around the steerer.

shafty
shafty
6 years ago

@’Merika Could you afford it? It’s all custom, so I’m sure the right per$on could make it happen.

You’d be better off with M5 for that.