The Beginning of Internal Routing

The goal has always been to have as much internal routing of the cables as possible, but to hopefully not cause catastrophe by weakinging the aluminum. Besides the cleanliness of the look, this being a commuting bike means that the more internal connections there are, the less there is able to steal off the bike. The big thing is the battery, but external junctions are at risk too. I have two paths in mind for the routing. The first, is running the cable from the display THROUGH the handlebars, throught the stem and then down the fork meeting the internal junction in the downtube. This would be the cleanest way. Problems would arise with drilling holes in the aluminum bullhorn bars. There is definitely conflicting reports on both sides of the argument, but really why risk changing the structural properties of the handlebar and causing them to fail. I could just buy predrilled handlebars, but would still have to have a hole in the center of the bar opening them up to the stem. The second option, which may be a little safer, is to drill a hole in the down tube and route the cable there, bypassing any holes in the handlebars. SO far, I am leaning towards option ONE and made a few routing holes in the fork. If I stick with option one I will prbably get steel or predrilled bars for some piece of mind.

 

As you can see below, I used a 13/64ths bit to make the first hole which lets the di2 cable slide through perfectly. Then i opened up a 45 degree angle with a 7/32 to ease the angle the cable needs to pass through.

 

 

image image image image image

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7 thoughts on “The Beginning of Internal Routing

  1. HI

    I have been reading your blog about the display with Ultra, can you help me out with connecting the display to Ultra 6870 Di2 shifter/disc?

    • Hi Richard,

      I think the best diagram I produced is here: https://seasonalcommute.files.wordpress.com/2015/04/image.png
      The mechanical layout is specific to my trike but the electrical interconnect will apply to any installation. You might not need the extra junction box, or you might need a different type of junction box (Shimano makes one that is intended to be mounted externally, near the bottom bracket). Also, I used the Alfine display, I assume that’s the one you’re using. Shimano now makes a different display for the XTR component group but I don’t know much about it, my advice would be to stick with the Alfine display. And of course you can go without a display– in that case you would replace the display with the cockpit junction box. The wiring is the same. As far as I know, any of the shift button assemblies should connect to either the display or the cockpit junction box. I like the Alfine shifter but you could also use any of the road shifters and (maybe) the mountain (Di2 XTR shifters).

      If you’re planning to run the Ultegra Di2 front derailleur with the Alfine display, you’ll be short one port. In this case I think you can use one of the passive junction boxes, but I haven’t tried it.

      If you give me more details on your configuration I might be able to give you better information. Or just ask if you have specific questions.

      kurt

    • Oops, I got confused about who was asking who what– sorry Pseudonym: James. Richard, he can probably help you out. And feel free to check out a similar project that I documented here: https://seasonalcommute.com/2015/04/10/trike-build-phase-i-ultegra-di2/.

      If you started with the setup that Pseudonym: James describes in his post titled “The Setup”, all you would have to do is replace the Alfine motor with the Ultegra 6870 derailleur and then reprogram the system with the eTube software. All those components should be compatible.

      kurt

      • Hi guys

        Thanks for your reply My goal is to mount internal di2 on a Cannondale road tandem which is not prepared for this so this will be fun too..

        I have been connecting it exactly like is showmen in the drawing (of your link) and yes, then it works great.

        But, as soon as I connect the SM EW 90 junction box, which I need for the left shifter and charging, the party is over

        Any solutions for this? Thanks Richard Op 6 jul. 2016 om 05:17 heeft Pseudonym: James <comment-reply@wordpress.com> het volgende geschreven:

        Kurt commented: “Oops, I got confused about who was asking who what– sorry Pseudonym: James. Richard, he can probably help you out. And feel free to check out a similar project that I documented here: https://seasonalcommute.com/2015/04/10/trike-build-phase-i-ultegra-d

  2. Are you connecting the SM EW 90 junction box and the Alfine display in the same circuit? That won’t work because they are both effectively bus masters. If you want to use the Alfine display with two shifters (one for the front derailleur, one for the rear), you’ll need to add a junction box (not the SM EW 90) between the display and the shifters to get enough ports. Note that you charge the system through the Alfine display. Or you can eliminate the display and connect both shifters to the SM EW 90, which is the way it was intended. If you are running both a front and rear derailleur, I’m not sure the Alfine display is a good choice as it may only show you the rear gear setting (I’ve never tried it with a front derailleur). Or are you talking about the XTR mountain Di2 display? As far as I know the Ultegra groupset doesn’t have a display. A list of the specific components you’re trying to hook up would help.

    • Hi James

      I know it’s not a normal connection but wanted to try anyways. I have another tandem without the display but the same parts only 10 speed

      Okay, the following

      Shifter left Shifter right Junction box SM ew 90 b Internal battery Junction box b Front derailleur Rear derailleur

      This above is the standard set and works well without display

      I just wanted the display to show the gears of the rear derailleur

      I got an Alfine SC S 705 display , no XTR

      Have attached photos of the junction boxes. Don’t know if you will see them [image2.JPG] Have updated with e tube

      Saw an article on another blog, handsonbike and thought it might be possible [image1.JPG] Regards Richard

      Op 6 jul. 2016 om 20:01 heeft Pseudonym: James <comment-reply@wordpress.com> het volgende geschreven:

      Kurt commented: “Are you connecting the SM EW 90 junction box and the Alfine display in the same circuit? That won’t work because they are both effectively bus masters. If you want to use the Alfine display with two shifters (one for the front derailleur, one for the re”

      • Ah, OK. I’ve seen a couple of references to combining the SM EW X cockpit junction with the Alfine display, but both of them mentioned flakiness, and I don’t think the most recent hardware and firmware supports it anymore (if it ever really did). I couldn’t get it to work, but didn’t try very hard.

        In my opinion a much safer bet is to follow Shimano’s guidelines and only have one cockpit junction in the circuit. This leaves you three choices:
        1) Stick with the SM EW 90 and skip the display. This will give you better battery life as well as the ability to adjust the derailleur without hooking up a computer with the eTube software. It also gives you the same resolution as the Alfine display for battery charge, using LEDs.
        2) Replace the SM EW 90 with the Alfine display. You’ll need an extra “dumb” junction box between the display and the shifters to provide enough ports. I haven’t tried this but I think it will work. But it’s messy to add another junction box on your handlebar. I’m also not sure whether the Alfine display will show you any information about the front derailleur.
        3) Replace the SM EW 90 with the new XTR display unit. This gives you the extra port you need (cleaner install) and will give you a gear indicator for both front and rear. But it won’t get you synchronized shifting, that’s a feature exclusive to XTR at this point.

        Good luck and let us know what you wind up with!

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