Aaron Pelttari's Toolbox - World Cup Mechanics

Jun 8, 2017 at 12:20
by Richard Cunningham  


bigquotesIt's very minimalistic. I've done it long enough now that I know what I actually need and actually use on a bike.

This week, Pinkbike photographer Ross Bell heads over to Team Canyon to investigate the arsenal of tools and supplies that Aaron Pelttari brings to keep Troy Brosnan's Sender podium-ready for the next World Cup downhill. Aaron hails from Australia, so almost every World Cup is a trip at least halfway around the globe. To minimize his travel expenses, he has reduced his cache of tools and spares to exactly what he'll need to work on Troy's bike.

Like many pro wrenches, Pelttari started with a bare travel case and then built it out with customized "pallets," which are hand-cut foam, populated with tools and layered according to importance. Carbon fiber is his material of choice for tool-clip back boards and the hinged compartment where he stashes lesser-used items. What strikes us most is what he doesn't have in his box. Compare Gwin mechanic John Hall's four-layer masterwork with Pelttari 's box, and it seems like he forgot to bring his tools - which has become a running joke between the Canyon and YT camps.
Aaron Pelttari Tool Box
Carbon fiber back-plate with clips for an Abbey Tools Titanium soft hammer, an Abbey Chain whip/cassette spline, a 3/8" ratchet and digital caliper, Abbey aluminum top-cap and bottom bracket sockets, a grease injector, a stack of stick-on temperature sensors, and a 1/4-inch socket wrench adapter. Flanking those is a pair of scissors, and on the right, the all-important sharpie for blacking out labels, and a ball-point pen for jotting down notes


Aaron Pelttari Tool Box
The entire kit: Aaron only uses one foam pallet, preferring to store many of his essential tool inside the confines of his case. A bungee-cord serves as a towel dispenser, and to the far left are cosmetic spares and a clipboard used to record suspension changes and racing information.


Aaron Pelttari Tool Box
T-handled Allens and Torx tools, at the ready in custom slots, next to a small-parts organizer, double-stick tape, tubeless film, a spoke tension gauge and zippered bags filled with spares and lesser-used items.


Aaron Pelttari Tool Box
Essential box and open-end wrenches, tire levers, razor knife, Mavic spoke key, tape measure, drift punch, Bondhus Allen keys, and a barrage of pliers: mult-use, needle-nose, circlip, and two offset cutters for cutting tires.


Aaron Pelttari Tool Box
The rat's nest: Pelttari crafted a hinged compartment occupying the right side of the box from carbon panels that houses a jumble of tools that he may need in a pinch like cable cutters, a brake hose trimmer, a leather hole punch, an automatic zip-tie tensioner/trimmer, and a third-hand tool.


Aaron Pelttari Tool Box
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68 Comments

  • + 50
 That's funny!Today I was going to buy some Abbey tools until I thought to myself...who the fuck do I think I am spending this amount of money on tools.
  • + 3
 Good tools just are more fun to work with. I just bought a set of the rainbow colored PBaumann hex and torx keys. No regrets!
  • + 1
 @SleepingAwake: they are definitely the sexiest tools out there.
  • + 1
 Their only tool worth spending money on IMO is the Crombie, especially if you happen have a bike with Campy on it, you can get the double-sided one. But yeah, it's sooooo much nicer than using a normal lockring tool and wrench, and it's not horrendously expensive either.
  • + 26
 I'm excited to see the super unorganized mechanic who just throws everything in a box haphazardly.
  • + 9
 I can send you some pics of my setup if you want.
  • + 6
 @DrPete: look at this over achiever putting his tools in a box!
  • + 4
 Would love to see toolboxes of some privateers in comparison!
  • + 2
 @Burnhardx: if you really want to see a bunch of tools thrown into a golf shoe bag i'll take the effort to snap the photo for you
  • + 4
 Amateur. You haven't really made it in the amateur mechanic ranks until you've glued a tool to your workbench with spilled tubeless sealant.
  • + 11
 Still needs a thingamajiggy though.
  • + 5
 I assume Aaron has a chain breaker and chain lube somewhere in there? I also wonder if he has cone wrenches and a derailleur hanger alignment gauge as these can take up a lot of space.

Interesting that the cable cutter is relegated to the "rat's nest". It is one of the tools I use most often.
  • + 1
 The chain break is on the foam insert. It's conveniently placed in the shadow in both pics. If you look at last weekends pit bits on vital there a shot of his box that it can be seen in.
  • + 8
 Probably not a hanger tool, just bin it off and fit new ones, you could carry 100 alloy ones in the space and weight of the tool!
  • + 2
 @cunning-linguist:

Doesn't necessarily mean it's aligned though.
  • + 1
 @cunning-linguist:

Agreed with Jordan604, I've had new ones that need tweaking to align right.
  • + 3
 You can check your spares and tweak spare hangers ahead of time. And also use a bunch of other tools to adjust one close to perfect in an a pinch.
  • - 6
flag clarky78 (Jun 9, 2017 at 11:19) (Below Threshold)
 Hanger alignment tool is total crap. You can align any hanger by eye to tolerances that work percectly. If you can't your eyes are bad or you suck as a mechanic. Every time I have been forced to use the tool it has proved that I already aligned it fine and that the gears are fuggered for another reason.
  • + 0
 @clarky78:
Nope.
  • + 5
 Been waiting all week for this. They said one from each round. I can only assume that this is from round 2 and that there will be another posted next week from Leogang . Can't wait !
  • + 2
 The Scottish still water bottle by his tool box would indicate this was done at Fort Bill.
  • + 4
 @DirtyDee: So does the number plate on the bike in the opening pic.
  • + 3
 @ryanlaf12: Pfff, too obvious! I like looking for the more random clues!
  • + 5
 I know I'm a bike nerd when I'm lusting after that Knipex set more than most of the bikes in the pit walk article. NERD!
  • + 1
 I ask you all mechanic experts here on PB the following: can one use a Shimano 36-26 B2 crankset (new boost model) with a non-boost hub 142x12? Is the 3 mm offset in the chainline really that drastic? I currently own a boost frame but will move to an “older“ 142x12 rear axle frame, will rebuild the rear tire with a 12x142 hub but the question now is this chainline. If it really messes up the gears, should I get a new non-boost crankset incl chainrings or just a new non-boost crankarm on the drive side? Thanks!
  • + 1
 Go to the mechanics quick question thread in the forums
  • + 1
 Call me snobby or autistic, but the tidiest thing around my bike itself and the surrounding is my toolbox. Labels above every slot for the pliers, matching compartments for my ratchet box and everything neatly arranged. But the best thing: It's all made by Hazet, so even my grandchildren will have fun with the tools. If you buy these, Abbey suddenly seems to be reasonably priced Big Grin
  • + 6
 Those Geman pliers.....
  • + 4
 Pedro's cassette clamp/holder. best bike tool i ever bought. stick chain whips up yer chuff
  • + 5
 wwooowwwww
  • + 5
 exciting, right?
  • + 5
 @Hundin: I enjoy these a lot, I'm almost surprised how open they are being professionals, you think it would be under wraps.
  • + 4
 A titanium hammer? is that stashed next to the marshmallow bearing press?
  • + 1
 I see no torque wrench anywhere. I guess if you're experience enough you know what each torque feels like but I was surprised in the age of carbon everything to not see one. Or maybe I missed it.
  • + 3
 Where are things like bearing presses in these boxes? You see them being used in photos but never in the toolbox checks
  • + 8
 Bigger tools, things like presses, truing stands, etc... usually live on the team truck. These toolboxes are the mechanic's personal setups, the essentials that they carry around the world with them.
  • + 1
 @mikekazimer: I can make a bearing press outta a hammer and a beer can, but these guys not having a truing stand they've spent years bonding with seems crazy. Maybe I'm just a wheel guy...
  • + 3
 minimal rules, why take tools you don't need ?
  • + 3
 Anyone knows were to purchase those t-handles allens?
  • + 1
 Company that makes t handles like that is called Beta
  • + 2
 Pretty sure those a the Silca sliding T-handles: silca.cc/products/57c424fc56d9341100298881-1
  • + 2
 Its sad but I have been heavily using a set of T handle hex and torx for a few years now with no issue other than the ball end snapped on the smallest. As a German, you will wince when I say they came from Lidl. £9 from the centre isles of toss.
  • + 1
 Feedback Sports makes some that are similar. Pretty nice.
  • + 1
 @ChristophColombo: Possibly but I believe silca has red writing on the tool. It might be Beta 951
  • + 2
 Does anyone know the size of these pelican boxes ?
  • + 3
 At a guess (using the hammer as a scale), 1520 or a 1550
  • + 2
 i've got a Pelican 1560 and it's perfect, the wheels are a nice added extra as well
  • + 1
 Thanks. Def must be the 1560. I have a 1520 and these have way more room.
  • + 1
 Apologies for being a N00B to the Pelican Boxes, but how do they get the custom foam for the tools? Are they marking and cutting & removing the foam to fit each tool themselves?
  • + 1
 @zepper: seen a video , and they basically trace around the tool they choose with a felt , and they cut it too the desired shape and depth required to hold said tool . The foam is KANBAN foam from what I remember , it,s special foam that is layered together.
  • + 2
 @cheetamike: kaizen foam, same word family. Can be acquired on amazon
  • + 1
 @kaneswan: that,s the stuff Thanks!!!Smile
  • + 1
 automatic zip tie tensioner and trimmer?
more info pleeeeze
  • + 2
 @sir-hc: I had no idea! Smile I guess electricians/IT workers must need em?
  • + 4
 @sir-hc: £623.00!? Does it fabricate the ties as well?
  • + 2
 @nojzilla: I've used them in the past when working on big generators, its critical to get the right torque to ensure you dont break the cable tie or the thing being clamped doesn't move.
  • + 1
 @fattyheadshok: When you are using 500 cable ties on the generators, does make the job a lot quicker and no nasty sharp edges left behind!
  • + 1
 @Eddiebaby: there Are smaller cheaper versions, we used to use them building pumps. Really handy things!
  • + 1
 As a former pro mech I love seeing what the factory guys use, thanks PB!
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