Final modifications

I wanted to nudge the generator roller a little higher on the sidewall of the rear tire to see if it would run a little more quietly and hold up better. To do this I had to cut away some of the fender.

I had tried using files and a Dremel tool to remove some plastic. Those methods removed almost no material. Rather than use more force, sharper blades or coarser implements at higher RPMs I went to the elegant power of the light saber.

Cafiend home and shop mechanic light saber kit

The trusty Chinese knock-off of a Swiss army knife has served as my light saber many times.

Lighting it up

I had to repeat the heating process numerous times to maintain a heat level that provided a smooth cut. Light saber technology is rather primitive as yet.

The roller has plenty of clearance in this smooth arc.

Setting the generator height and angle made me scrutinize the rear rim. A telltale small hop directed my gaze to the section where a small stress crack has developed at one spoke eyelet. This is the life cycle of the modern wheel. This rim is six years old and has more than 12,000 hard miles on it. It's the third wheel on the Cross Check since I built the bike in 2000. Since 2000 I have ridden this bike more than any of my other options. The rainy-day fixed gear probably comes second.

New rim is on order. The Salsa Delgado Cross served me pretty well, but I'm liking the Sun CR 18 these days. It has a triple-box construction and is still lighter than the Delgado. They all crack eventually. We'll see how it goes.