Integrated Headsets To Storm Road Market In 2002

FLETCHER, N.C.—Bike makers used integrated headsets in 2000 and 2001 to set themselves apart. But those smooth oversize headtubes that hide the bearing cups will be a little more ordinary in 2002 as more and more manufacturers latch on to the trend.

"Product managers told me the trends for 2002 are compact frames and integrated headsets," said Peter Gilbert, Cane Creek's vice president of sales. Cane Creek makes many of the integrated headsets on the market.

Those who use the system claim it has many advantages, but others warn the designs are not up to par. Many said it's a fad that is likely to go away in a couple years.

Schwinn was one of the first to broadly use integrated headsets. Its ICBM design uses a cartridge bearing that fits directly into a specially machined aluminum headtube. While the design differentiates the Schwinn bikes, designers claim it has structural advantages.

"This is far from a marketing gimmick. If designed correctly, you can make the frame lighter and stronger with this system," said Mark Pippin, Schwinn's director of product development.

Giant uses a slightly different system in which a cup sits inside the headtube.

"The tolerances have to be high. If you mess up with our design you can just replace the headset—but with in-frame cups, you have to replace the frame," said Dennis Lane, Giant's director of product development.

Many designers remain unconvinced, however, that the benefits of the system outweigh the risks. Headset guru Chris King was so intent on avoiding internal headsets that he issued a press release on the subject in March.

"We are at a loss to see any substantial advantages to the rider beyond cosmetics. We have definite structural concerns with the young and relatively unproven designs of the current integrated systems," the King release read.

Making a frame to accommodate the headsets is more difficult and more expensive.

"Trying to weld a frame perfectly straight then machine it perfectly is not an easy operation. And using the frame as a bearing cup, I don't think is really the way to go," said Chris Hilton, Easton's bike product manager.

Schwinn and Giant, and a growing number of other manufacturers, particularly in Europe, believe in the system, in large part because the headtube is larger in diameter and stronger tubes can be welded to it. They claim the system is just as reliable as traditional headsets.

"There are no more warranty issues than normal. We haven't seen any big issues," Schwinn's Pippen said.

Mountain bike frames with internal headsets can have their own unique problems. Because the height of the headtube and headset cups is lower than a bike with a standard headset, some suspension forks can hit the downtubes, damaging them.

And retailers and consumers are still getting used to the headsets.

"We get more and more calls from dealers and consumers who don't know what kind of headset to use on these frames. They don't know what type of bearing to use or how to measure chamfer for the bearing," Cane Creek's Gilbert said.

While road frame makers want forks that have the same diameter at the crown as the headtube, fork makers are frustrated by the lack of standard sizes. Current forks are a centimeter or smaller at the crown than the outer diameter of most integrated headtubes—enough to look a little out of place.

Fork makers also are waiting to see if the headsets are more than a fad.

"We are waiting for it to settle out to see what the standard diameter will be or whether it will even be around very long. It's a cool-looking trend, but I'm not sure it's going to be around long," Easton's Hilton said.

Making a fork specifically for the system would force fork makers to redesign the forks and retool their molds, both expensive propositions.

"We would have to invest a lot in tooling and engineering and then you run the risk of having obsolete molds and forks," Hilton said.

Cannondale solved the problem by having Time make forks of its own design. Cannondale uses Campagnolo's Hiddenset on all its internal headset CAAD 5 and 6 road bikes.