Just be aware that you will, depending on the Lefty and the age of said unit you’ll use and how many parts you will have to manufacture, it will set you back between $1000.- and $2000.- Plus Bucks!
But anyways, here we go:
There are two ways to go about for a 2012 and newer Hooligan (2009-2011 are another story entirely as they have a 1 1/8 head tube that is 21mm shorter).
A couple of important measurements before we start:
But whatever way you choose you will need a custom length steerer Tube made… (the Hooligan head tube is 191mm tall, no standard Lefty and or Steerer tube will fit) I designed one and had a run made of them (Overall length: 340mm):
https://fotos.mtb-news.de/p/2101517?in=setYou have to maintain the crown height of 420mm (distance from the center of the lefty axle to the bottom of the lower bearing).
https://fotos.mtb-news.de/p/2047178?in=setVersion ONE:
Using the older Lefty with movable Bridges like the old DLR, PBR, SuperMax, Jake, etc. (build from 2000 to about 200
.
(Easily recognizable by the rubber boot, and NO you can’t use the fixed or glued ones or the Carbon ones!!!) (They can not be internally adjusted to reach the required Crown height, you’ll drive around like you are riding a Downhill bike!)
The used Lefty can be found for quite cheap online like eBay or used Cannondale bike sites. Be aware that almost every one of them will need a service, so add that to whatever you pay for it.
https://fotos.mtb-news.de/p/1591316?in=setAdjusting the crown height is achieved by moving the lower Bridge further down (the fork is designed for 26 inch wheels and we are using 20 inch), You will have to machine the upper Fork tube by extending the notch by about 20mm to 30mm, depending on the fork used.
https://fotos.mtb-news.de/p/1591417?in=setNow as stated before, the Hooligan head tube is 191mm (add another 10mm for each bearing cup, top and bottom as we have to use the Lefty Bearings or Headshok bearings for the Lefty sized which is 1.56 inch), the largest distance ever used by Cannondale MTB’s was the XL fork with 137,5mm. So you will have to machine a new upper Bridge to create the gap of 211mm!
https://fotos.mtb-news.de/p/1779167?in=sethttps://fotos.mtb-news.de/p/1796899?in=setSo as you see, this version is “cheaper” if you already own one and have access to parts or a machinist!!!
Version TWO:
My preferred one (sexier one) and expensive version… as the Lefty is newer and ergo very much expensive to purchase… and of late not easy to find!
I use the Lefty Hybrid carbon version ($$$) also known as the Lefty 1.0 Carbon. Easily recognizable as there is no rubber boot! And it’s quite slick and tinny looking in comparison to the Lefty 2.0 which adapted the measurements from the Hybrid SuperMax! (The diameter has grown by 4mm! and the lengths of the bridge by 2mm, small but important aspect as you will find a little later!)
https://fotos.mtb-news.de/p/1794655?in=setWe are using the Carbon version as we have to remove the lower bridge to expand the bridge gap to the aforementioned 211mm, actually 214mm including the dust cover and the crown bearing shim!) Unfortunately the aluminium version can’t be centered as its a forged piece and the measurements are all over the place! With the Carbon one, you end up with a perfect round tube…
https://fotos.mtb-news.de/p/1591419?in=setThe beauty of using the Carbon version is that you don’t have to mess with the top as you get rid of the lower glued one and you can just buy a “new” lower Bridge by using a removable Bridge from the discussed old Lefties (in Version one). They are fairly cheap to buy and easy to find… again the old DLR, PBR, SuperMax, Jake, etc. (build from 2000 to about 200
. Still needs some minor mods, the keyway has to be removed and a 1mm shim has to be added to make for a secure fit!
https://fotos.mtb-news.de/p/1803883?in=setThe crown height is adjusted internally with shims. So it does not matter what version you buy as they are all the same (130mm) and are internally tuned to 120mm or 100mm (29-er)… with a crown height of 420mm the lefty ends up having a travel of 80mm. Way more then you’ll ever need on the road! (That can be done by who ever services forks in your area, I don’t mess with the internals to much, so I send it in to Eighty-Aid and tell them that I need the aforementioned Crown height, they add 10mm spacers until reaching the required number and they tune the rebound accordingly!)
Unfortunately that whole scheme does no longer work with the Lefty 2.0 or the new SuperMax (discontinued as of this writing!) as the measurements have changed and the Lower Bridge no longer fits… I am in the process of converting a SuperMax carbon as we speak and am building a custom lower Bridge to make it work!
https://fotos.mtb-news.de/p/1975917?in=setSo beside the Lefty Hybrid Carbon (2013/2014) you will need the following parts to make it work: Overlong Steerer tube, top and bottom Headshok cup with bearings, Upper dust cover, Crown bearing shim, star nut, rivet, Lower Bridge and Bridge Shim:
https://fotos.mtb-news.de/p/2109012?in=sethttps://fotos.mtb-news.de/p/2109014And here is the final Product… I have done over 3000 Kilometers since I finished the fork, It’s now on my second Hooli, it was originally on my Bersker and now is in my Pinion Hooli. I have build 6 Hooligans with Lefty so far… I am currently in the process of converting another Hybrid Lefty for a friend of mine…
https://fotos.mtb-news.de/p/2147860?in=set Just be aware that the mods done to the Fork are non reversible (Cannondale does not sell upper tubes separately) and will void any and all warranty requests! Also the Fork is no longer off road capable as you would put to much strain on the lower bridge which could lead to failure!
So I hope that makes any sense to you as I wrote most of it from memory!
Hope that helps,
Sincerely,
Erwin
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