Project Bike - Scott Plasma 3

This has nothing to do with coaching, or athletes, but it has a bike involved, and it was a fun custom build project that I wanted to document and share somewhere.

I like to time trial, probably my strongest personal discipline. I like the man/machine integration and just like putting it all out there without a lot of head games.  Scott Bikes happens to be a generous supporter of the US Military Endurance Sports Elite program, but sponsor arrangements aside, I have always been a fan of their Plasma 3 time trial frame.  The stem/top tube integration just looks really cool and I love the "Flying Tigers" shark teeth on the stem of the full TT version.

In the first couple of years of release, they had a TT configuration with a flat stem and was only usable with Di2 electronic shifting, and all of the cables routed internally (and tediously) through the bars, stem and frame for a super clean look. Oh yeah, and it tested fairly well in the tunnel, and it happens to fit me well, but mostly I just liked it and all those other things were bonuses :-).

Unfortunately, the "TT" version with the full internal cable routing and the flat shark stem saw very limited public release. However, after some investigation, I discovered that with a few carefully implemented (but somewhat nerve racking) modifications, the readily available consumer version could be adapted to the full TT version's former glory. I have built up most of the bikes I have ever owned, so know my way around fairly well, so as a custom project, I decided to set out to see if I could create my own version.  

In the end, it took on a life of its own and the final build ended up with a custom paint job from Hot Tubes.  Here is the photo documentation of the multi month effort along with some build notes (hover over or click the pictures for the comments).  Hope you enjoy and can appreciate the end result!

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Here is the base Plasma 3 frame, drilled for Di2 electronic shifting.

I used some creative junction box connections, and the mounts for old style Di2 Battery to tuck the junction box away underneath the Bottom Bracket.

The most nerve racking step. The stock fork is partially setup for internal routing, but required some mods to the 1 inch steerer to allow the brake and Di2 cables to pass through. Dremel tools were very handy during this step.

The Plasma access door was very handy for internal routing, labeling your cables is important in a Di2 setup!

Was able to use a new style Di2 battery and just tuck it into the seat tube. It fits snugly and doesn't rattle.

Usually pretty organized, but things got a bit messy during the build.

Oliver the cat did not approve of the mess or the slow pace of progress.

Here is version 1 of the full build with stock paint.

Close up of the bar, stem integration.

Integration was great, but the stock paint schemes were mis-matched.

I was happy with the fit and function, but the color mismatch didn't do the rig justice, so I looked for custom paint options.

Went with Hot Tubes for paint. After many design tweaks, we came up with this. Minor "body" work was done to fill in the stock holes to complete the "clean" look.

Again with the cabling, very tedious. The most challenging build I have ever taken on. Note Dura Ace 7800 brake, frame was designed to use this brake only.

Chris King bottom bracket for smooth rolling and easy service. Another shot of the junction box setup.

The yellow is gone, but the distinctive shark teeth remain. The front brake cable running to the Tri Rig brake is the only external cable on the build.

Front derailleur routing is as clean as it gets thanks to the Plasma access door. SRAM rings work fine with Di2.

Close up of refreshed top tube.

Di2 handling the shifting duties, super smooth.

Much cleaner integrated look.

No much sticking in the wind. No holes, no cables and cleaner top tube to stem graphics.

Build 2 w full paint and "training" wheels.

Bar end and brake lever shifters are a big benefit of Di2. 3 small junction boxes in the bars and stem allow 1 cable to run to the BB.

Oliver is quite done with the build.

Race ready, just in time for winter!