Iron Horse Sunday Reborn - A Classic Downhill Bike Modified with Modern Geometry & Mullet Wheels

Jan 18, 2022
by Matt Beer  
All photos credit of Christina Neubauer.

Back in 2004, Iron Horse debuted the iconic Sunday downhill bike that used Dave Weagle's DW-Link suspension design, which was a departure from the previous Horst-Link SGS model. Made popular during Sam Hill's era of dominance, Hill and the Sunday were an iconic duo with their flashes of magnificence on two wheels and metallic green paint. Much like the Intense M1 before the turn of the century, the Sunday became a common sight among privateers World Cup racers due to its proven capabilities.

Iron Horse dissolved as a high-end mountain bike company in 2009, but the Sunday made such an impact on the downhill race scene around the world that privateers and bike park regulars quickly bought up spare parts stock. Pivot Cycles' original Phoenix downhill frame was chirped by riders for taking some inspiration from the Sunday and trying to reincarnate original Iron Horse fans. One composite company, Zelvy, even made plans to manufacture a carbon front triangle to mate with the hardware and rear triangle of the existing Sundays, but the product changed form to become an entirely new frame, the Preston.

With all of the mystique surrounding downhill legend, Sam Hill, and the extinction of Iron Horse, it's no surprise that we still talk about those racing feats today or that riders wish for a Sunday with updated geometry.

Iron Horse Sunday Rebuild Details

Wheelsize: 29" front / 27.5" rear
Reach: 470 mm
Chainstay: 460 mm
Front Center: 840 mm
Wheelbase: 1300 mm
FC/RC Ratio: ~ 1.83
BB Height: 340 mm
Head angle: ~ 62.5 degrees
Fork Offset: 48 mm
Weight: 19 kg


Well, that's exactly the kind of project Austrian downhill racer and skilled machinist, Julian Neubauer, challenged himself to take on - an Iron Horse Sunday with modern angles and numbers. His goal was to arrive at a Sunday frame with his ideal geometry, but also meshed with a 29" front wheel and 27.5" rear. The process involved not only sourcing, chopping, and re-welding a frame more than a decade old, but also piecing together a suspension fork with equal complications. We got in touch with Julian to ask a few questions about what prompted him to try this, what challenges he ran into along the way, and what he plans to do with the revitalized bike.



Don't be being afraid to try.

Can you tell us a little about how you got into mountain bikes?


I started mountain biking around 2008, specifically downhill in 2009 after I was spectating at the World Cup final in Schladming. Little did I know I was going love it so much. Immediately after that race I got my first real mountain bike; a white Specialized Big Hit. A couple days after I got it I was riding in a bike park and had such a big crash. I wasn‘t allowed to ride for weeks after that, but things ramped up when I recovered. I was a pre-runner at the age of thirteen and raced my first Austrian National races in 2011.

What inspired you to buy an old frame, cut it up, and spend money on new tubing when there are plenty of great bikes out there these days?


I always loved the look of the Iron Horse Sunday. I love the look of straight tubes and sharp angles. And clearly because Sam Hill absolutely destroyed every track with those bikes. There is just something about railing an open turn, foot-out, flat-out. And since those bikes are not made anymore, I wanted to give an old bike a new life. Over the years of riding I noticed what characteristics I liked and I didn’t like.

Fast forward to 2020 and COVID... I was searching eBay when I stumbled upon an Iron Horse Sunday frame which had an "ok" price tag. I had some spare money and thought, why not? I realized you don’t have to have the newest parts and bikes to have fun. It’s about the feeling and passion. I started by buying this whole frame from someone in Germany. It had spare linkages, derailleur hangers and everything you need to build up a new Sunday. When I got it, I was super stoked and could not believe what I had.

During the pre-weld process I stumbled upon a single front triangle. It was quite cheap and I thought, before I cut the only frame I have into small pieces it would be smart to try some ideas first. This was our first try for me and also for my welder. And actually buying an old frame is like around €300-400 and the tubing wasn’t that expensive too so why not? I am really lucky to have friends that can weld aluminium and only want a pack of beer as payment haha. So I got a custom made frame for much less than a new frame from any bike company.

What parts did you need to modify for re-use from the original frame?


I took an old Iron Horse Sunday frame and cut out everything I needed. This included the head tube, seat tube, plus the CNC part connection to BB and the gusset from seat tube to top tube for the front triangle.

For the rear triangle I used the old dropouts and the bearing mounts. Then I ordered some tubes for the main frame and rear triangle to be able to accommodate a 27.5” rear wheel. This was the most difficult part for me. In Austria it is not common to use these alloys like 7020, 7005, 6061 or 6069. But I found a company in Germany who sold me a couple of tubes for both the front and rear triangle. I also changed the geometry of the front triangle while I was at it. It’s like a XL Sunday if you want.

Are you a welder or machinist by trade?


I completed a technical trade with all sorts of machining operations, but it’s not my profession. Maybe I should start thinking about becoming one! After that I studied sports equipment technology in Vienna. I think it’s quite fun to explore and tinker with geometry, materials, and so on. Some of my friends are welders and machinists, which I am super grateful for. They helped me create this piece of art into a reality.



Were there any issues with the triangles twisting in the jig?


I did not notice any distortion. We only spot welded the frame in the jig. The big welds were made with the frame not being in the jig. I think it’s similar to how frames are welded in factories. This was already the second prototype. The first one we kind of pushed it against the wall because we had no frame jig. The geo was really weird, but rode alright. The BB was too high and the head tube angle too steep. But we solved everything with the new frame.

Would have been easier to build something from scratch from steel or aluminum?


I would say no. The main reason for me to use a donor frame was because I wanted to create a “new/modern” Sunday. If I had to machine all of the parts myself then it would have been much more expensive. But there are some companies that already offer dropouts, tubes and what not if you want to build your own bike. However, those parts may not have been suitable for downhill use.

For the fork, you machined your own crowns and used Boxxer stanchions with 29" Lyrik lowers? What offset did that result in?


Yes. I stumbled upon a report about the “Rockshox Lyxxer”. There I read about the custom made Boxxer crowns. First, I thought I may be able to use the crowns from the new C1 Boxxer, but unfortunately, the spacing between the stanchions was too far apart. Then I started to measure all of the available RockShox stanchion spacings. They Lyrik spacing was in between the old and new Boxxer. I took all the necessary measurements and constructed them in Autodesk Inventor. A very good friend machined them for me out of 7075-T6 aluminium. The steerer tube is made from a different material, but I don’t remember exactly which one I ordered. I used the black stanchions from the B1-B2 Boxxer with 29 inch boost Lyrik/Yari lowers. I did not want anything crazy for the offset. I aimed for an offset of around 48 mm.




I take it you are a big Sam Hill fan then?


Big is an understatement hahaha. This dude is my biggest hero and I would love to have Sam Hill's and Brendan Fairclough's signature on this bike since they raced the silver green Monster Energy edition Sunday back in 2008.

Are you planning to ride this bike?


I am planning on doing everything I can with this bike. It is my absolute dream bike. I have a spare Kona Operator Carbon frame that I removed the paint from in my basement, but I am really excited to ride with this new Sunday until death sets us apart haha.

Where do you ride most of the time?


I try to ride many different downhill tracks, but I mostly ride in Schladming and Semmering. Semmering is around fifty minutes from where I currently live. Schladming one of my favorites, for obvious reasons. I would have done anything to race the Schladming 2007, 2008 or 2009 World Cups. That would have been my dream come true! Especially with my Sunday!

What races have you competed at in the past?


I mostly compete in Austrian National and European Cups. Occasionally, I try my luck at World Cups. My goal is to qualify for a World Cup with the Sunday I made.


You can tell that this shop has some stories to tell and is a fun place to hang out.




Julian would also like to add, "A big thank-you to my good friends, the welder and the machinist, who helped me create this wonderful machine. Also thanks to everyone involved in the process. This is a dream come true!“


218 Comments

  • 195 0
 hi this is Julian! Smile
thanks for all the love and feedback. recent years have been rough and these comments/bikes certainly brighten up my day. i can't wait to ride it.
thanks so much for this insanely awesome story article about the project
keep it up yall
pinkbike frontpage = one dream came true
Julian aka @westagil
  • 8 0
 Would it be possible to get some DIY manual or what tubes, how long are needed for this build?Thanks
  • 21 0
 This is hands down the best looking bike ever made, again! You have done a brilliant Job man, you are the envy of... well, everyone!! Congratulations!
  • 7 2
 Awesome work, now get those frames annealed/heat treated!
  • 2 6
flag schofell84 (Jan 18, 2022 at 16:25) (Below Threshold)
 Oh, try 4943 filler if you're welding 6061t6 and report back for me please. Smile
  • 6 0
 these types of builds are amazing, I love all the work, keep it up!
  • 1 0
 Have you ridden it yet @westagil ? We need to know how it feels in action.
  • 1 0
 Great read! I love this bike the original brings back fond memories. You didn’t a fantastic job blending modern wheels/geo but maintaining the original look! I was traveling the US racing nationals in this era and always wanted a Sunday but it never worked out sponsor wise.

May I ask why you didn’t use an off the shelf 29” boxxer?
  • 4 0
 @chakaping: unfortunately not. i had problems with my shoulder last year and needed surgery. i still only can ride around a little bit but will update as soon as this machine gets wild in some dh tracks. Smile
  • 1 0
 Nice work, that is an awesome project
  • 3 0
 @meathooker: thanks! i really appreciate it!
i wanted to keep my tuned charger and the coil spring. the new boxxer does not come with coil springs (by now there is a coil conversion kit i believe). and after all it was cheaper to buy a lyrik lower leg and machine the crowns then to buy a new fork and coil kit and so on. Smile but if i get my handy on a new boxxer 29 i would like to play around with different tuning stuff.
  • 1 0
 @student: hey!
the process from cutting it up to finished frame only was a few weeks.
  • 1 0
 From the same request as @student, I would like to have more photos and manuals to make my own homage!
  • 3 0
 @Notmeatall: and @student

I appreciate your request but this is a one off project for myself. I also am not allowed to do things like this also because i don‘t own any rights for ironhorse or the dw-link patent.
At this point i still am waiting for Approval for the frame to be safe to ride. There won‘t be a kit for a diy or anything like it. Thanks for the interest tho
  • 1 0
 Respect for you and project !
  • 1 0
 @westagil: Ok. I respect that. Now I'll go back to the drak room!
  • 1 0
 Hi Julian ! I'd definitely would be intesrested on getting in touch. Got two frames standing, and I have this kind of project in mind for some time now.
  • 100 2
 Such a beauty! Also, is it just me or are the comments centered now, instead of left aligned? Not a fan.
  • 14 0
 same here,looks terrible and confusing
  • 123 0
 Left aligned comments are now an Outside Plus™ feature.
  • 8 1
 They’re normal position on iPhone
  • 50 0
 Engineer with a BMX background here - found the problem

Inhereted from div
#content-container .center {
text-align: center;}

You can inspect the text and unclick that to fix for now
  • 3 0
 Ha! Now they're back to normal..?
  • 2 0
 Same here... I thought it was my computer and restarted it but no... it's confusing indeed. Pinkbike! What the hell!!???
  • 2 1
 They look normal on my browser here at moment, maybe fixed?
  • 52 18
 I have always tried to be centered - Left aligned comments get on my nerves
  • 11 1
 @calmWAKI: "calm" waki? How did you get there?
  • 9 2
 @calmWAKI: You're "calm" now? You've changed man, you've changed! tehe, glad to see you back Waki, assuming you're the real Waki.
  • 13 10
 @bashhard: Shitake mushrooms and managerial role, working on a challenging project with great people geared to work hard outside their comfort zone, take responsibilities and just cooperate towards making it happen despite differences and variety of backgrounds. Cooperation between humans is great. So blessed bro. MTB could never give it to me
  • 37 9
 @calmWAKI: you’ve never been centered, except existing in the center of your own universe.
  • 9 7
 @nickfranko: ultimate burn + underrated comment
  • 4 1
 @calmWAKI: good for you Waki Beer
  • 2 0
 @nickfranko: “Emotional DAMAGE!”
  • 82 0
 “My goal is to qualify for a World Cup with the Sunday I made.”
That would be amazing to see the Sunday in a World Cup again, fantastic project that looks epic and up to date!
  • 42 0
 I don't have those welding skills in order to make such like this good job, but in the same state of mind and with help from a machinist, my old '02 Stinky followed almost the same way: www.pinkbike.com/photo/19717527
  • 3 0
 This is genius! I was worried your seat angle would be in horror territory, but as it turns out, you've taken that into account too. Very impressive solution
  • 4 0
 @doubleohshreddin: Thanks a lot. My good old fellow Stinky is used for many years only as my DH bike, then the seat angle is not a big issue anyway :-)
  • 1 0
 congratulations! i like it!
  • 1 0
 ok, that's a brilliant bodge. nicely done.
  • 1 0
 @xy9ine: I'm not quite sure of the meaning of "bodge" but, well... thank you ^^
  • 1 0
 Well friggin done, I love it! I bet this bike is a tonne of fun.
  • 1 1
 @Zarma: bodge is typically utilized to describe a janky fix, but probably not a fair use in this case, as that looks pretty damn tidy. i like to think of it as an endearing way to describe an unconventional yet effective solution.
  • 4 0
 @onawalk: As much fun as my skills allow, yes! I don't argue to need more suspension travel nore efficiency. I'm a sentimental and this bike followed me across the ocean when I came back to France from Canada in 2007, he's a quite part of my life! In french we say "c'est dans les vieilles marmites qu'on fait les meilleures soupes".
  • 1 0
 @xy9ine: All right, I catch it! You can see the details of the assembly in my other photos.
  • 1 0
 @Zarma: This is a beautiful saying. Love it!
  • 31 0
 **Evil laugh** Buys up classic bikes for pennies before the MTB restomod scene gets in full swing and prices skyrocket

***Cackling intensifies*** Uses proceeds to build bike park with dedicated area suited to old skool geometry
  • 3 0
 Too late for that!
  • 1 0
 I was just thinking actually - if Singer did DH bikes... Haha
  • 26 2
 That's sick. I hope you. Heat treated it and have good insurance
  • 8 0
 I'm gonna bet no on the heat treating.
  • 15 1
 I was scrolling through to see if anyone mentioned that. So many heat affected zones with so many welds, it should be heat treated for sure. RIP Julian.
  • 2 0
 Hmmm...was wondering about that. It'd be interesting to hear from a welder or materials pro about the science of strength without heat treatment.
  • 3 0
 @PHeller: Wikipedia says welding T6 6061 knocks it back to somewhere around T4, which means a drop in yield strength of around 40%.
  • 6 0
 @azureblue: my first hand experience is working at a shop and seeing highly skilled welder repair the head tube on the front of a 2003 norco 4 hun, and adding additional gussets etc. looked legit!!!. lasted about an afternoon when the kid came back with a bloody face holding frame and fork in separate hands. was weaker then ever.
  • 36 4
 hello !
I am the dude in the pics. thanks for all your responds!
i studied materials for about 8 years. i made one frame in beginning of 2021 which i rode over the course of 2021 and there were no issues in strength whatsoever. i even got more tired and felt more vibrations than when riding other bikes.
there is a artificial aging technique where you simply let it sit for 2-3 months in order for the material to rekristallize and get back to around 80% of its strength. since the old frame parts are made from a different alloy than the new tubes i got there is not a perfect solultion as for treatment. i talked to some people and some of them recommended a small heat treatment, but i am not 100% convinced. I am aware of what can happen and am really into servicing and maintaining a bike. i will check regularly for cracks or similar. i have trust in my welder.
cheers tho
  • 3 41
flag wiscodh (Jan 18, 2022 at 13:17) (Below Threshold)
 this is a wreckless (well soon to be a wrecked frame and person) article by pinkbike if this frame is un heat treated and this "expert" materials guy has a front-page story.
  • 42 2
 @wiscodh: hello!
well i did not say i was a expert. i am certainly noo expert but as i said i sudied material for some time now and have been in touch with some of austrias best material scientists, my welder also is one hell of a experienced guy. i wont say its not gonna break. but the frame we welded and rode last year held up very well.
i am already a reckless person so why not ride a reckless bike.
cheers
  • 8 12
flag mammal (Jan 18, 2022 at 14:08) (Below Threshold)
 @wiscodh: I wouldn't say the article is reckless, but the project is a bit sketchy without heat treatment.
  • 30 0
 @mammal: your sketchy without treatment
  • 10 0
 @wiscodh: I understand why you'd say that, but this article is not reckless because pretty much no-one is going to follow in his footsteps. Exactly how many PBers with no welding experience will see this article and decide to crack out the TIG welder their grandfather left in the shed? Yet anyone can launch themselves off a cliff regardless of skill which makes articles on Rampage more dangerous than this one.
  • 7 1
 @westagil: which alloys did you use on the new tubes? The US-made Sunday Team/Factory was 6069 aluminum. If the lower spec, overseas models weren't 6069, they would have been 6061.

6061 should not have been difficult to find - it is a globally abundant aerospace aluminum - pretty much any other option (7000 series, 2000 series, or 6069) would be more exotic. Also, you should not be welding 7000 or 2000 series to the original 6000 series components, so I'm going to hope/assume that you used either 6061 or 6069. In that case, a T6 treatment is absolutely appropriate for both alloys, and necessary for this frame to function safely. Expect to have to do some cold re-alignment after the heat-treat, as it will warp. Good luck.
  • 1 21
flag wiscodh (Jan 18, 2022 at 21:03) (Below Threshold)
 yeah, ya know what, screw it, post picutes video of the carnage in a month or so pls. thanks! Should make for some good Friday fail content. GL bud.
  • 11 1
 @wiscodh: lol what a bitter human being you are. Wishing someone on Friday fails....
  • 3 10
flag wiscodh (Jan 18, 2022 at 23:23) (Below Threshold)
 @Imabigboy82: nah when people don't listen to actual experts. You reap what you sow. There are many experts in this thread pleading for him to heat treat this project. Kid dosentwant to hear it so, good luck out there.
  • 2 0
 @wiscodh: Thats fair enough, I just wouldn't want to wish it on anyone is all.
  • 5 0
 @westagil: Being in the industry making and testing frames of all sorts i strongly advise you to find someone that can heat treat 6 series material and do some sort of basic testing. I guess all tubes are a mix of 6061-6069 so that will work. Look at Iso 4210 or consult Zedler. Without destructing it, you can load it up to a threshold deemed as the minimum acceptable. If it does fail at such low load, well... better it's in the lab than on the trail. That Head tube in particular is sketchy. You have increased the angle, removed the reinforcement gusset and not heat treated it.
Good job on the welding fixtures though. that's cheap and functional!
  • 1 0
 @FlorentVN: thanks for the input! thats a great idea!
  • 2 0
 @FlorentVN: good catch on the missing gusset! I just assumed he followed the structure and wall thicknesses of the original. 100% please add a properly designed gusset - it doesn't have to be the same as the original Sunday, but at least use a convention from a dual-crown-rated frame that has been fully engineered and tested. And as I noted above, heat-treat the frame. Please.
  • 15 0
 Woah, can we get Sam to do a hot lap or three on a WC course for nostalgia?
  • 11 1
 I hate to be an internet jockey, but please get this alloy heat treated if not already after welding. After welding, the heat effected zone is now compromised in strength and controlled heat treatment will help uniformly bring that material strength back closer to its pre-welded temper, very importantfor nonferrous alloys. You can even test this theory with a calibrated surface hardness tester by taking sample readings from parent tube to weld bead within a joint location. Any reputable heat treat shop should be able to help. Be safe and rad project!
  • 12 0
 My man ! This is so class fucking big fan here fair play to you !
  • 3 0
 thanks man, i truly appreciate all of the love and feedback
  • 3 0
 @westagil: Dude very nice job, nothing wrong with building your own toys!
  • 11 0
 Just in: Sam Hill will take this Iron Horse and whoop everyone's ass at this year's worldchamps
  • 9 1
 incredible work, it looks beautiful. I've been dreaming of something similar. Does anyone know why the Franken-fork was made, and why wasnt a new 29" boxxer or fox 49 used?
  • 15 0
 hello! i am the dude from the pics! thanks a lot!!
i wanted to run the old boxxer things with a 29 inch front wheel. since there is a different thread in the new boxxer stanchions i couldn't you the coil kit and charger from the old boxxer in the new boxxer.
i tuned the charger with an andreani piston kit and was running a extra hard raceonly spring.
and since i wanted to recreate the old sam hill 2008 val di sole bike i wanted to give the forks a "blackbox" treatment
cheers
  • 4 0
 @westagil: That is awesome dedication! Deserves a story in it's own right! Thanks for sharing!
  • 10 0
 Make mountain biking straight tubed again
  • 14 1
 buy nicolai
  • 6 0
 Minor correction: Sunday debuted in '04 under the IH/Mad Catz team (Sam Hill, Bryn Atkinson, and Mathieu Laurin). Bike was available to consumers starting in '05. '03 was the last year of the SGS, with Rennie riding it to a WCDH overall.

I remember really liking the wide-legged cowboy stance of the 100mm BB shell on the SGS. Having the derailleur way out there with the 165mm rear hub, on the other hand, was kind of a drag...
  • 5 0
 ETA: in '03 Hill also rode the SGS to his second and final junior World Championship. #themoreyouknow #earthed
  • 3 0
 @DirtCrab: Huge Earthed fan over here too. I'm not sure how I arrived at '03 instead of '04, but thanks for the catch!
  • 1 0
 @mattbeer: All good! You've been absolutely killing it, keep up the good work. And that's coming from someone who interviewed for your job Smile
  • 5 0
 Still one of the best looking bikes ever. I had a love/hate relationship with mine back in the day: Loved how it rode; loved how it looked; hated how it constantly rattled itself apart and killed bearings at an alarming rate. Would have one again in a heartbeat if I could justify it though.
  • 1 0
 I question why no one has bought the Iron Horse IP and revived the brand. It keeps happening to Ellsworth! I know IH had a rocky ending but overall I would say it’s a solid brand. Imagine MUSA aluminum frames that actually functioned.
  • 4 0
 @rivercitycycles: It got bought by Dorel and turned into a BSO supermarket brand. They killed the brand, for sure, but I think it's long enough gone that nobody would remember, and anybody who knows the name isn't going to care about what happened back then.

Shall we approach Dorel and see if we can go 50/50 on it?
  • 2 0
 @speedfreek: IH doesn’t deserve it current fate. It deserves to be ridden at 40mph down the courses. Always dreamed that someone will approach them with an offer…
  • 2 0
 I've still got my Sunday. Just recently took it all apart and rebuilt it. Still in very good condition.
m.pinkbike.com/u/Goose76/album/Mobile/?inList[]=21944686
  • 5 0
 @westagil: If it's all 70 series of some kind, you can just let it age for 3 or 4 months and you'll get back to pretty decent strength. Otherwise without a heat treat... not a great idea to ride a frame with 6061-0 joints! But it's your life and your bike, of course. Keep in mind that you'll want to check/fix alignment after annealing but before heat treating.

Maybe you guys heat treated it and just didn't mention it? For something like this it is probably doable in a pizza oven since the bike breaks down into pretty small subassemblies
  • 5 0
 Someone in Germany did the same thing with a Sunday, there was a whole story about it a few years ago.
Gotta love these projects
www.mtb-news.de/news/bike-der-woche-ironhorse-sunday-275-replica-von-ibc-user-bigair92
  • 2 0
 I knew I'd seen a similar project somewhere, I figured they'd lifted it from V****
  • 6 0
 Wow what an amazing project! Cheers to you!

Way more work went into this than my Resto-Mod 08 Turner DHR Mullet.

www.pinkbike.com/photo/21860165
  • 2 0
 Oh man, that is so beautiful! I have an 08 frame hanging in my living room as decor. What did you use to polish it?
  • 3 0
 @kcy4130: Mother's polish and a few days! 3 different grit sand papers, 2 cloths.
  • 7 0
 So cool, I think we need a few more modern takes on old classics!
  • 4 0
 I wish this was a business and not a one-off. How many other awesome bikes could be modernized with just some simple tweaks and a refresh? What a great way to eliminate waste and build truly special rides!!! Kudos Mate!!!
  • 2 0
 I'd like to show up on a modernized Big Hit, 29/27.5 Mullet of course, replete with 3" stroke Avalanche remote reservoir shock.
  • 3 0
 Smile would be the dream if you could order a new sunday or turner dhr today.
thanks mate!
  • 1 0
 @preston67: The E. Euro scene would be so green with envy
  • 1 0
 @preston67: Avalanche is running strong. Got them mod up a DPX2 and a lyrik and my god its an amazing difference. Worth every penny.
  • 8 2
 Is it just me or why tf are all the comments centered all of a sudden?
  • 2 0
 here too...
  • 4 3
 It’s just you.
  • 5 0
 You’ve done exactly what I had day dreamed about!

Now do a Giant ATX 1 DH, A GT Lobo and a Specialized Downhill Team!
  • 5 0
 "trying to reincarnate original Iron Horse fans". Wow. How many fans died? What did they come back as?
  • 3 0
 Horses?
  • 4 0
 I love it!

(Even though metallurgically, this is a really bad idea and could produce a frame that's potentially unsafe to ride.)
  • 6 4
 Sketchy welds, old tubes and different new materials with no heat treatment… can’t wait to see the next article about the catastrophic failures ahead. Good luck nice job in doing what you want in life, even though most people wouldn’t seriously ride that bike, it’s cool to see something like a iconic Sunday in the Pinkbike news besides more stupid Ebikes or new hub standards.
  • 2 0
 I did something similar 2 years ago.
I went to Leogang, Schladming and many other European places with my Sunday "Ultimate" 650B
I tried to destroy it but it is impossible Razz
The frame after welding was heat treated(solution treatment and aging).

www.pinkbike.com/photo/21945695
  • 5 0
 Put this bike in mass-production!!
  • 4 0
 Sam's bike had that head angle 15 years ago and the bike industry never caught on as to why it was so fast.
  • 3 0
 That's awesome, always loved the Sunday. Unlike the new outside banner across the top. That is not awesome in the slightest and I do not love it.
  • 3 0
 Forget the haters @westagil. The bike is sweet, and they aren't riding it, heat treated or not. If you feel safe with it, and feel confident in the construction then run it.
  • 1 0
 @westagil I don't suppose you measured the geometry on the original Sunday before you chopped it up? It's surprisingly hard to find a reach number (or the othet numbers we use these days) online for them.

Bike looks amazing, very impressed!
  • 2 0
 Roughly these numbers. 400mm reach on a medium. 420mm reach on a large. 65 degrees head angle. 350mm bb height. 440mm chain stay.
  • 1 0
 @DH1977: why do i have some memory a Medium's reach was around 377mm?
As for HA, some frames had 65 degrees, and i think there was a 2009 version that had a 65.5-66 degree HA, not sure why. Positive side of this is the headtube was 1.5 - ideal for extreme anglesets. I sold my Sunday with a -3 degrees custom angleset i rode for several years without issued and with great confidence and pleasure! Smile
  • 1 0
 This is an excellent article; great pictures, writing, and content. Thank you!
As an aside, I bet this will raise the value of my hardtail Iron Horse Warrior Comp I'm still riding from the $20 I bought the frame for to $30 or possibly even $35!
  • 1 0
 Hey again:
I wanted to add that this is a one off project for me and personal useage only. I am no expert on bike building, i simply want to try and create something unique. I don‘t know yet if i can ride this bike safely, i hope so but i am going to have another welded frame tested to be sure it holds up. I am not going to give out instructions on how to do it. And i am not going to build a bike for you. If u make your own you must be aware that it might not be safe to ride. It is your decision and your own responsibility. I do not take any credit for any crashes or technical failures whatsoever but i think this is clear.
Thanks again for all you support and feedback. It has been an unreal 24h.
  • 6 2
 Maybe Toby Henderson will start racing DH again?
  • 3 1
 Comment of the year comes early.
  • 6 0
 That would be “THE” day!
  • 3 0
 The Sunday is the most beautiful DH ever designed with the possible exception of the c. 2009 V10.
  • 4 0
 Quality content. The Sunday was a legendary bike.
  • 7 0
 *is a legendary bike Smile
  • 2 0
 @mattbeer does julian have an instagram he is willing to share where we can follow the story of this bike and his racing career?
  • 2 0
 hello!
yes, its me haha @westagil
just hit me up
  • 1 0
 The only thing cooler than the bike would be if he manages to qualify for a world Cup on it. Awesome work - I have 2 Sunday frames on the wall here that I'd love to see converted like this!
  • 1 0
 Love Iron Horse (I have 3 Warriors). Always wanted a Sunday, the old SuperGo bike store would have them and I wanted one sooo bad! . Had kids so no extra $. (kids are grown now and still no extra $, WTF!)
  • 1 0
 Damn this is awesome!! I remember wishing I could afford a Sunday back then when I first saw one. Shortly after I had an iron horse hardtail back in like middle school. This Sunday reborn is SICK!!!
  • 4 1
 Oh my god, my life is complete!!!
  • 1 1
 mine is too now Smile
  • 2 7
flag ligament (Jan 18, 2022 at 13:15) (Below Threshold)
 @westagil: no
  • 2 0
 This is amazing. Thank you for putting this project together for us to see. And thanks to PB for posting. Love this
  • 1 0
 thanks mate! i love it so much how you all love it too
  • 2 0
 Rad, the Sunday was and still is a brilliant bike, yeah they had their issues but rode awesome. Good stuff.
  • 4 0
 Quality article.
  • 2 0
 Amazing work AND amazing shop,I feel like at any time a DJ can pop up and play some bossanova vinyls.
  • 2 0
 thanks! i will let my welder know whatg awesome shop he has Smile
  • 3 0
 I STILL HAVE MY SUNDAY!!! hook me up!!Awesome job
  • 3 0
 please update my 2010 spec sx trail...but keep it 26 inch wheels
  • 4 0
 That workshop is art.
  • 1 0
 Can you heat treat with a torch? I’ve heard of a company would re-heat treat the I beams on steel bridges for months on the same spot to harden it.
  • 3 0
 You'd want an oven of some sort for this. A pizza oven can get plenty hot and you can fit the frame (in parts) so that would be an option if you don't want to pay the couple hundred bucks to have it done professionally.

A torch will just ruin it (more).
  • 1 0
 @waltworks: alot of pizzas when that frame is done.
  • 1 0
 That looks fantastic! If they started producing Sunday frames like that, I would definetly buy one for my next DH build. Nice work!
  • 2 0
 This is one of the coolest things I have seen in a long time. Well done!! Good luck at the races
  • 1 0
 460mm chainstay - holy moly.

Was that what you wanted or just a design necessity to fit a 27.5" wheel into the rear triangle?
  • 1 0
 I had an Iron Horse MkIII back in 2007, but the more I look at the Sunday, the more it reminds me of the Banshee Rune V3 I ride now.
  • 1 0
 Just makes me wish I kept mine, learnt to weld and cracked on! Amazing nostalgic article seeing a Sunday frame again! Love it!
  • 1 0
 chamfer those fork crowns! sharp corners are easily damaged, and chamfers have the additional advantage of being kinder to fleshy parts. =)
  • 1 0
 great bike! no idea how to extend my frame Sunday to XL lol .. too complicated re strength by mixing old and new. BTW i wave wielding machine but not experienced yet.
  • 2 0
 My Sunday was the most memorable bike I've ever had
  • 4 2
 Am I the only one seeing centre-justified comments?
  • 1 0
 Judging by the several other comments indicating the same, no it is not just you.
  • 1 0
 @stumphumper92: seems back to be back normal now
  • 1 0
 I still have my old Sunday frame in the loft, if only I had the skills etc etc etc
  • 2 0
 It must be an Iron Wild Horse with weldings like these, (Crom)holy cow!
  • 2 0
 I’ll take a set of the Lyrixxer crowns please
  • 2 1
 Yo, @notoutsideceo these new outside+ adds are insanely annoying. Stop putting them on our account pages!
  • 1 2
 I'll do you one better! try.bravesoftware.com/dgf367

Be safe be well,
Incognito Robin
  • 1 2
 @notoutsideceo: You could also not do “invasive adds”.
  • 2 0
 the iron horse looks alot more interesting then a regular horse
  • 2 0
 Awesome job Julian, loved seeing the progress on that thing!
  • 3 0
 Great Job Julian!
  • 2 0
 thanks mate!!! love the feedback
  • 1 0
 Make sure you carry about 34 spare shock pivot bolts with you. Those frames ate them once a shuttle!
  • 2 0
 Excellent job, one of, if not my favorite DH bike
  • 2 0
 So the DW link patent is up in 2 years? interesting...
  • 2 0
 Please make it a real available bike for all of us
  • 1 0
 No heat treat, lno oem style gusset, slacker angle? Headtube launch in 3.. 2.. 1.
  • 2 0
 YES
  • 2 0
 I WANT ONE!!!
  • 2 1
 Center justified comments just to F$$$ with us all.
  • 1 0
 If i could weld my Straight 8 would be a monster
  • 2 0
 I'll take 2.
  • 1 0
 Apart from this great project, what a magic place!
  • 1 0
 Isn't the new Atherton bike essentially a modernized Sunday?
  • 2 1
 "Don't be being afraid to try."

So about those concussion protocols
  • 1 0
 Is this related to Marvin Mührer 's custom Iron Horse sunday from 2018?
  • 1 0
 Awesome job! I was a big fan of the sunday. This thing is rad!
  • 1 0
 I really want to know how it rides.
  • 2 0
 RAD
  • 2 0
 Bring Ironhorse back
  • 2 3
 It's didn't need Mulleting back then and it doesn't need Mulleting now. It was fast enough on 26" wheels so will be absolutely fine on 27.5 wheels now.
  • 1 1
 Yep.
  • 2 1
 But he wanted to make it contemporary to 2022, not 2016?
  • 1 0
 "An Iron Horse Sunday with modern angles and numbers. His goal was to arrive at a Sunday frame with his ideal geometry, but also meshed with a 29" front wheel and 27.5" rear."

Nope.
  • 1 0
 Wasn't Iron Horse bought up by Trek?
  • 2 0
 Nope, Dave Wiggle and Trek sued each other for the Split Pivot/ABP patents.
IH went bankrupt and was bought by Dorel, i think it was called - who transformed it into a supermarket brand...
  • 1 0
 Shut up and take my money
  • 1 0
 Rad. Though the Ship of Theseus springs to mind...
  • 1 0
 I cannot like this enough.
  • 1 0
 Need this done to a square tubed Turner dhr
  • 1 0
 What a blast from the past! Takes me back.
  • 1 0
 + Paunger the Welder. Hard work is paying off boys, top job!
  • 1 0
 Very cool. Always loved the Sundays!
  • 1 0
 Should've added water bottle mounts. ;-D
  • 1 0
 Very cool!
  • 1 0
 Sick!
  • 1 0
 very cool
  • 2 5
 Everyone is so eager to poo on Orange bikes welding and not one comment about this?? Seriously sketchy. But congrats on getting it done. Building a bike from scratch or not is not easy.
  • 7 1
 One is an established company that's been around for decades and the other is guy in his basement building something for fun
  • 1 0
 Yeah where are all the comments on the welding!? PB must have mellowed!
  • 1 1
 I agree with you dog shit welding on a dog shit frame. It should have been left original. Just look at the seat tube brace it already looks cracked all the way through lol
  • 1 1
 @BillT999: orange welds are professional welds and look it this just looks like a steamy mess of shit.
  • 1 0
 Totally awesome!
  • 2 1
 DAYYYYUUUMMMM DANIEL
  • 1 0
 Awesome work!!
  • 1 0
 Eetadik
  • 1 0
 Such a cool project
  • 1 0
 Rad project m8
  • 1 0
 厉害!!!
  • 1 2
 Hmmmm….should just let that classic be and not Frankenhorse it….
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