MAIDEN Model Products home page

 

Kool Cap installation on Graphite wheelsGen I Kool Caps for Zytel Tuff II'sGen II Kool Caps for Zytel Tuff II's

24" Wheel Installation Solutions

 

Gen I Kool Caps

Tuff II installaion page

Including 20" Zytel Nylon Tuff Wheels.

20" Tuff II front wheel with a Gen I Kool Cap installed.

This is the installation page for the installation of Gen I Kool Caps into 20" Zytel Nylon Tuff Wheel II's.

FAQ's:

1. I know other people have done it, so I know that it can be done, but, how can I do it?

2. Why don't they just fit the same as they do on the Graphite wheels?

3. Why don't you make them all fit the Tuff II's right out of the box?

Answers:

 The reason that the Gen I Kool Caps have not been advertised, or marketed, for this installation is due to the primary difference between the Graphite Tuff Wheels, and the Tuff II's. The Graphite wheels have what is called the "Convertible Hubs" installed in them. These are all metal hubs, and they are the same consistant diameter front and rear. So, the Kool Caps naturally fit both Graphite wheels perfectly. Tooling costs allow MMP to make them to fit that one size hub. To make separate tooling for a different (varying and inconsistant) size of a front hub is not cost effective. Effectively, the recent run on the Tuff II compatible Gen II Kool Caps, is a test run.

The Tuff II's have a much smaller metal front hub molded into a surrounding pocket of Zytel Nylon. This configuration means that the front hubs on the Tuff II's, are not sized as accurately as the metal convertible hubs on the graphite wheels.

In truth, they vary from about .008"- .018" (thousandths of an inch) larger than the aluminum rear hubs, and the aluminum graphite hubs . But they are are not consistant, as there is some taper in the molds, and some expansion, and contraction during the mold process, and there is also what is called "mold flash" around the edges of the wheels. This makes it impossible to know exactly how big the plastic area of the front hubs will be from wheel to wheel.

Installing the Gen I Kool Caps onto the new Skyway Tuff II wheels is not terribly difficult, but does require some care and thought, as well as a few tools that not everyone owns.

So, installing the original Gen I Kool Caps onto standard Zytel Nylon Tuff Wheel II's is actually a "do it yourself project". You do so at your own discretion, and at your own risk to yourself, and your wheels.

If you want a set that fits right out of the box, you will need to order the new Gen II Kool Caps for Tuff II's, which are available now. Those will fit right onto both the 20" Tuff II's, with no modifications to your wheels necessary.

Where to begin?

For starters, you need to be safe, and wear all the proper safety equipment, such as safety glasses, and have some familiarity, and confidence, with use of the tools shown in the process.

Begin with a basic Dremel hand tool and a small rotary bit.

Remember: This only has to be done to the front wheel of the standard Zytel Nylon 20" wheel set. The rear wheels already have the correct sized metal hubs.

Shown below is the plastic mold flash which is the first thing to be removed. This provides you a little bit of a practice piece. When removing this flash, hold the tool at an angle shown and install the wheel into a front fork, or into a wheel truing device, and simply spin the wheel in the opposite direction of the cutting tool. You don't have to spin it very fast, and you have to be mindful of the tool in your hand as you spin the wheel. Spin the tool very fast, and spin the wheel at a slow coasting speed, and apply very gentle pressure to the tool. Work slowly. Wear your safety glasses, as the tool will be spitting little bits of plastic right at your eyes, and blowing them around with the airflow from the tool's internal cooling fan.

Once you get the feel for it, and the flash burr is gone, you can begin to remove some of the material from around the hub where the Kool Cap is to be installed.

Work slowly, and gently. Rest your hand on the forks or truing stand, and be very steady with the tool. Only remove a little bit at a time.

A pattern will start to form in the plastic. (Shown below) This is not from having an unsteady hand, this is actually showing the inconsistancy in the size of the plastic hubs, as it removes all the high spots.

Check size frequently, and hold the tool perfectly parallel to the hub. Do not stick the tool too far in, and engage it into the plastic spokes.

You only need to remove about the thickness of a piece of masking tape, wrapped once or twice around the hub.

When you have finished cutting the wheel down to the exact size of the Kool Caps, it will look like this.

All you need to do at this point is use some 220 grit sandpaper, or a small file to deburr the sharp corner where the mold flash was.

Then you can simly install your Gen I Kool Caps onto the wheel with pure silicone adhesive, exactly as shown on the Graphite installation page.

The first time I did this, it took me about 15 minutes. But, it's not a race, that is only to give you an idea of how long it takes to do this adaptation.

Remember to work slowly, and carefully, and wear your protective eyeware.

 

Shown above: Front Tuff II with Gold and Silver Kool Caps.

Available now in: Gold, Silver, Blue, and Red!

 


To Purchase Kool Caps:

Simply click on "Add item to cart" below, and you will be directed to a secure Pay-Pal web link. Visa, Master Card, or Pay-Pal accounts can be used. You do not need to be a Pay-Pal member to purchase these through the secure link.

There will be a fixed $8 dollar shipping fee attached to all orders on this site.

This Includes the USA, UK, Canada, and Australia. Please inquire for other regions before placing orders. The Pay-Pal shopping cart link automatically adds the shipping fee of $8.00 to all products on the web-site. (This is due to the common html code used for automatic checkout, and carrying a wide variety of products.)
 

The benefit to you, is that this creates a discount for multiple set orders. You save $8 per set for each set after the first.

 

See details below to purchase securely with a Credit Card or pay directly with a Pay Pal account.

Item: Original Gen 1 Kool Caps in Gold  (Anodized, and brite dipped)
Specifics: Set of 4; Gen 1 Kool Caps; For Graphite Tuff Wheels




Price: $34.00

Item: Gen 2 Kool Caps in Gold: For Graphite Tuff Wheels (Anodized, and brite dipped)
Specifics: Set of 4; For Graphite Tuff Wheels




Price: $34.00


Item: Gen 1 Kool Caps in Silver. (Colorless anodized, and brite dipped)
Specifics: Set of 4: For Graphite Tuff Wheels or
Customized Zytel Tuff Wheel installation.



Price: $34.00


Item: Gen 1 Kool Caps in Red. (Anodized, and brite dipped)
Specifics: Set of 4: For Graphite Tuff Wheels or
Customized Zytel Tuff Wheel installation.



Price: $34.00

Item: Gen 1 Kool Caps in Blue. (Anodized, and brite dipped)
Specifics: Set of 4: For Graphite Tuff Wheels or
Customized Zytel Tuff Wheel installation.



Price: $34.00

Item: Gen 2 Kool Caps in Gold: For Tuff II's  (Anodized, and brite dipped)
Specifics: Set of 4;  For Direct Tuff II Wheel instlalations




Price:  $34.00



Item: Gen 2 Kool Caps in Silver: For Tuff II's  (Colorless anodized, and brite dipped)
Specifics: Set of 4;  For Direct Tuff II Wheel instlalations




Price:  $34.00

Item: Gen 2 Kool Caps in Red: For Tuff II's  (Anodized, and brite dipped)
Specifics: Set of 4;  For Direct Tuff II Wheel instlalations



Price: $34.00

Item: Gen 2 Kool Caps in Blue: For Tuff II's  (Anodized, and brite dipped)
Specifics: Set of 4;  For Direct Tuff II Wheel instlalations

Price: $34.00


MMP offers 100% satisfaction guarantee. Any items will be gladly refunded if the product fails to meet with your satisfaction. Simply return them promptly, and I will gladly process a refund.

Thanks to all for making these such a fun item!

 MAIDEN Model Products home page

If after browsing this website you have not found the information you are looking for please Contact Us!