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Top: Jared likes to stick his tongue out while filing down his dropouts. Bottom: Some pieces of Jared’s dropouts. Photos: Scot

While we were sitting around the office this morning, Jared came up with the brilliant idea to cut his dropouts. No, I’m not talking about converting his dropout from 3/8″ to14mm, I’m talking about shaving off some of the excess dropout. Now you may be asking yourself, “Why would you want to do this?” Well, to make a long story short, Jared and I have been trying to save as much weight as possible on our bikes. This was Jared’s new idea. I thought he was crazy, but in the end I was proven wrong. Although his dropouts look a little sketchy (some of you hardcores may be down with that look though), he ended up saving a half-a-pound. A half-pound may not seem like that much, but if you take into consideration that a frame weighs about seven pounds, Jared shaved seven percent of the weight off of his frame–not bad.

Make sure you use metal cut-off blades like the ones shown, don’t use a wood cutting blade like the one on the saw. Photo: Scot

Of course, there are some warnings that go with a tech tip that is this difficult and dangerous. First of all, make sure you get the correct blade for your circular saw. You don’t want to use the same blade that is used to cut through wood. This could very easily result in the loss of limbs and other assorted body parts. You want to make sure that you use a metal cut-off wheel. You can find this at any hardware shop for about two dollars.

Next, you want to make sure that you take the proper safety precautions. Pieces of metal are going to be flying everywhere and you don’t want one to get in your eye, so wear some safety lenses. We didn’t have any lying around the office, and Jared didn’t want to wait for a price check at the hardware store, so he just used some motocross goggles with clear lenses. Your frame is going to get very hot, so you’ll want to wear gloves to make it easier to handle.

The last thing that I wanted to mention is that if you aren’t experienced with using a circular saw, then you probably want to have someone who is help you out. Jared has worked at skateparks, so he is used to cutting coping. Also, if you’re going to be using your parents’ tools or doing it on their property, you should probably let them know what you’re up to.

Jared Souney gets suited up for a little metal work. Photo: Scot

Random Facts About This Tech Tip
1. Jared shaved roughly eight ounces off of his frame.
2. The cut-off wheel was 5/8-inch smaller in diameter when Jared was done.
3. It took less than 20 minutes to complete the job.
4. It now smells like hell in our warehouse.
5. Jared voided his warranty.
6. Jared’s bike still weighs more than mine.
7. Robbie Morales was stoked.
8. The Park Tools bike stand made this job a lot easier.
9. It was really loud and sparks were flying everywhere.
10. Ryan Sher (Kink) is doing his at the moment. (2:20pm Monday, February 12)