A Folding Military Bike is Born !

In 2009 when I came home for Chinese New year from Timor Leste i was seated beside a SAF Major who was on UN duties in Timor Leste. This guy competes in marathons and triathlons so when the subject of bicycle came up I told him I use a folding bike in Timor Leste. He told me there is a folding bike that is specifically designed for the US forces...the Montague paratrooper. I did  alot of googling and after three long years I finally saved enough money to buy a Montague Paratrooper frame through the Internet.. they sell the complete bike in Malaysia but I wanted BETTER components as I wanted to take this bike for touring. On top of that I have a friend Mr Ong in Kemaman who owns a bicycle shop and he will get the items that I need at no extra charge. i took this opportunity to ask him to guide me through the entire assembly process so that I can do repairs on my own when I am in Timbaktu later on!

We started with the fork. the original fork has a suspension system but for the time being I do not need a suspension so a straight fork will do. That saves me more than a kilo in weight.The brand chosen for me is Azonic and it is quite light. The spacer rings are fitted into the fork. that requires a bit of hammering through a pipe.

Mr Ong here having a careful examination of the frame

The fork is then fitted into the frame and bearings are then fitted both on top and bottom. a generous amount of grease is applied.

The shop has all types of components so it was an easy job..... just pick the best that is within my budget

Then the transmission is fitted. this is a very critical component and I selected the Shimano Acera 27 speed mountain bike gear set. it cost me a bomb!

The rear gear set is next fitted.

For this bike I have decided to use hydraulic disc brakes and had selected the Trek hydraulic brake set

The bike is almost ready after two hours . I had left Mr ong and his men to fine tune the bike

No problem on folding the bike . It goes into my campervan quite easily

To unfold it takes less than a minute!

I took the bike out for a normal circuit (38 km) and found it was a joy to ride (of course...with all the shinning gears!). The bike now stays in my stable of bikes at the back of the house.

The Aft Beam is joined

 After the "Big Job" of getting the two hulls level and square I am ready to glass the aft beam onto the hulls. this is real serious stuff as the hulls are held together with the beams. the beams are positioned on top of the saw horses that I had built earlier on. Blocks of wood and brick hold the beam high above the hull. The angle is then measured and cut.

 Strips of 200/225 biaxial matts and 600 gm CSM are cut and prepared. Epoxy is used throughout.

I had a part time helper for this job as I cannot carry the beam alone. As he had no experience I had to monitor all his work very closely. 

 

The saw horses were in position until 24 hrs later when the epoxy has hardened.

 The exterior part of the beam is also glassed.

 On the inside the 9 mm plywood knees were used to strenghten the beam attachment

 

After 24 hours, the saw horses were removed.

Setting the hulls LEVEL and Parallel

I had selected a spot in my garden that is relatively flat for the purpose of assembling my catamaran. The drop in gradient for 30 ft is about 2 to 3 inches. I guess I will be quite happy to apply chokes to the hulls  to find the final level. The boats water line would have been a perfect ref point but the reference is inside the hulls on the bulkheads and by now its markings would have been faded to the point of being invisible. That is the problem of taking too long to build one's boat!

I have a friend Dr Nik who is building his own house ( a portion of it) with his bare hands and he has the Laser leveller. He came over and worked out some numbers.

 

His laser equipment shows that there is a gradient of about 3 to 4 inches between the two hulls.

 

  His final solution is in order to ensure perfect level, some sort of a platform to house both the hulls must be constructed. Yes...that is the perfect solution but I am not prepared to spend so much time and money to get absolute perfection. I also remember that most Wharram designed cats only use rope to tie the hulls to the beam.

I resorted to the traditional way of using the pendulum bob and the leveller. Now one most important primitive equipment that I used was based on  the principle that water finds its own level. So a small transparent hose was purchased and I measure the hulls from a datum to ensure that the hulls are on a same  level and  perfectly up right.

 Several of these mason's levelling ruler were placed in various parts of the hulls

 A car jack came in handy to raise and lower the hulls slightly so that some pieces of wood or planks could be inserted under the hulls

 Finally my mosaic builder friend Ah Sang came over with his electronic leveller to confirm my work is acceptable. This time he came just before dark so that we can see the laser markings better. His theory is that he will mark several poles all around the boat with the same level. Later if I want to check the level all I need is a string pulled between the points of the same level

One other function of his laser equipment is he can also check whether both the transoms are in line or not. My son Alwin and my nephew was around so I had some extra labour to push the starboard hull 3 inches forward.

Gypsy Final Asembly Instructions

On the plans for the Final Assembly of the Gypsy 28 Catamaran it was just staed:

"Set up hull so that CL are 4100 MM apart
Ensure hulls are parallel and that diagonal distances are equal
Brace well, Fit aft beam and knees
Join cockpit to Cuddy as shown
Cut Mast Beam holes in Cuddy
Glue and Glass cockpit to aft beam "

Haha.. it sound so simple but I have been spending a lot of time wondering how to execute this.
Probably it will take me the whole of this year to complete the assembly.....The items are heavy and I could no longer work alone most of the time.

Repositioning the Gypsy pieces

 The hulls had to be repositioned to a relatively flat surface for the final assembly of the pieces.. I had also liaised with the "future" crane driver so that the boat once completed can be craned out of the house. There were some construction workers just across my house and I managed to talk to their boss for the use of some muscles to lift the hulls and the cuddy to its new position.6 workers came and with a lot of shouting and cheering we managed to move the two hulls and the cuddy (the cuddy was blocking the way initially)

 Some smart guys says we needed straps to lift the hulls but  we substituted that with some ropes and a rubber hose.

 With the two hulls in position we took the aft beam and position it right at the back of the hulls.

The cuddy was then brought in to its new position. The reason why I had to place the cuddy here is that I have no maneuvering room once the beams are attached to the hulls. At this position I think I can use rollers to roll it forward and aft when needed to.

 I now have an empty nest! This boat shed id vacant! It is just like having grown out kids moving out of the house!. Next....preparing for the assembly!

Trekking the Mat Kilau Trail to Kuala Tahan (12 to 15 May 2013)

While" playing "around the Ulu Dungun area in Pasir Raja I came to know that in the good old days the villagers used to walk between Kg Pasir Raja in Ulu Dungun (Terengganu) to Kg Bantal in Central Pahang. The locals used to visit each other's village just for a game of football or maybe to attend a kenduri(wedding reception). Measuring the distance in Google earth shows that the trail is about 125 km long and about 88 km is on the river. That leaves ONLY about 37 km of hiking. Of course that does not include the up hill and the downhills so the actual distance over the terrain is probably 45 to 50 km.

Later I found out that this trail was established by the legendary Malay Warrior Mat Kilau while escaping from the British rulers. It took me many more trips to find out more about this interesting trail. Of course talking to the local villagers will reveal plenty but I have to filter the facts from fiction!

What makes this trail interesting is that we will be trekking up to the source of the Dungun River go over the watershed and then go down along the source of the Tembeling River.

About 2 months ago my partner in crime  Sunny Cheong and I met a guy by the name of Lan in Pasir Raja. We started a conversation and I expressed my desire to look for a local guide to guide us to Kuala Tahan from the village. He told us he know of an experienced guide and would introduce him to us.

Pak Tar(the old man on the right of Lan) has been staying in Pasir Raja all his life and used to earn his living by collecting rattan from deep in the jungle. He has several relatives in Kg Bantal ( a very remote village in Central Pahang). After meeting up with him a date was fixed for the trip....12 May to 16 May 2013. May is a dry month and would be good for the trip. Just before the trip Sunny Cheong managed to recruit one of his golfing friends another Cheong CB to come along. that makes it 3 of us.Pak tar wanted RM 700 to be the guide and I did not argue on that.

 

 So on 12 May 2013 we assembled in front of Pak Tar's house for the first part of the trip which is a drive in a 4 WD vehicle to Mat Kilau's grave for the start of the journey. My brother in law Ban Chet had come along to take the car home. I had prepared an equal pack of ration for Pak Tar as I wanted him to enjoy the same foof that we had. To my suprise he refused to carry his food. I had no choice but to carry HIS part of the ration ! 

 

We drove towards the direction of Era Keling which is supposed to be a waterfall and by the time we reached the end of the road it was time for lunch. for lunch I had packed 6 packs of delicious local food from the stall .

 

After lunch it was time to cross the first river and get moving . The first part of the trail is on abandoned timber track and is quite flat . We were making good progress

Towards the end of the abandoned timber track we came to Sg Temaka which is a small tributary feeding into the Dungun river. From here onwards we tracked uphill along this small stream.

 

All along the trail we saw Bunga Kuantum which according to our guide is peculiar only in this area

On the uphill part we took frequent rest and at one point managed to get lines for our cell phone. Ops normal call were made to our families.

 

 Even the guide had to take frequent rest...He kept saying "naik bukit susah lah"..meaning going uphill is tough!

 

My new found friend Cheong CB was in high spirits! He was doing Ok even though he was a tenderfoot in this game.

 

By the time we decided to set camp for the day it was almost 1830 hrs. Both the Cheongs had to make a shelther

I had my Hennessy Hammock which took only 3 minutes to set up.After all my years of jungle camping I had decided a few years ago that the only way to sleep comfortably and peacefully is a good hammock. No more rock or broken branches under the body..

 

 While they were all busy setting up their shelter for the night I did the cooking.It looks like I will have to do this task for the entire trip! Never mind..since I cook I always get the best and biggest share of the food.! 

On the second day we had a simple breakfast of Oats and raisin and commenced our journey at 0800 hrs. 

 We were told that we would reach a water source after about 3 hrs hiking. 

 

Well we took 2 hours to reach the water source and cooked lunch here.

 Lunch consisted of pasta with tuna and some cabbage leaves. After this it is more climbing...all the way up to Bukit Main Angin which is about 2900 ft high.

 

At the peak we could use our hand phone again so we took a 15 min break . At this point Pak Tar the guide decided that based on our good progress we should be able to meet up with the boat man by tonight. He made a call to the boatman and requested the boat to be ONE DAY earlier..This is the border stone which divides Terengganu and Pahang. After this is it is down hill all the way. the track is quite well defined. At once stage I was stung by some bees. Luckily the others were quite a distance behind me and I had to shout to divert their treks to avoid being bitten by bees.

 

 There was quite a bit of undergrowth along the way but towards the Pahang side the jungle is still primary.

Kuala Gemala

Soon we realised that it was a mistake to arrange for the boat to come a day earlier. Cheong CB had cramps and we actually wanted to set camp at Kuala Gemala when we arrived at about 1530 hrs. Seeing that the morale was low, I decided to cook some hot food and we had a good rest before setting off again.

 The water in the streams here is very clean. I drank water direct from the stream.

 

We managed to coax out tenderfoot to life again. This time we were trekking along the Sungei Chey. By now all our shoes were wet . Fresh elephants tracks were sighted. We could smell the elephant here.As it was approach dark I decided that we should camp at Kuala Chey for the night. From Kuala Chey to Kuala Lurut where our boatman is will be another 2 hrs walk.

 

Some parts of the river can be quite deep....... it was very slippery as we walked on top of the rocks.

 

By the time we set up camp it was almost dark. The guide took the initiative to trek down to Kuala Lurut to assure the boatman that we are here so that he wont leave without us. Actually I thought it was unnecessary as the boat man will never leave without us (We had not paid him yet!)

 

Next morning we decided to enjoy the morning at Kuala Chey. We woke up late..at about 0730 hrs.

 

I found that in the darkness of the night I had tied my hammock just on top of some elephant dung. Luckily there was no smell! But I do feel some softness whenever my buttock touched something when the hammock swings.Real SHIT lah.

 

The river here is prestine......

 

We were enjoying the lovely swim on the clear water river . Not a sound of traffic or hand phone ringing! Share prices could bottom down so what.......Not a worry in the world!

 

The depth of the river is just ideal for a swim.

 By 1o00 hrs we started our trek along the Sg Chey again . This time we had to walk on the river.

 

This is where the local cap Gajah rubber shoes were idea. it provides better grip on the rocks as we went along. A walking stick makes the walk easier too.

The wild elephants had just passed us maybe two hours ago. Just compare the elephant feet to my foot!

 

The walk was slow and tedious. one wrong step and a fall is almost certain!

 

Soon we sighted OUR boat. No more walking.. Everyone felt great. We cooked lunch at Kuala Lurut before we boarded the boat to take us to Kg Bantal. Cost of hiring the boat from Kg Bantal to Kuala Lurut is RM 400.

 

Our boat man was En Noh..a very friendly guy.

 

By now all of us had enough walking so sitting on a boat is pure haven!

 

The boatlady (whatever she is called) can really multi task. She can help to navigate the boat through the shallow water, fish (very handy with a jala/casting net) and cook!

 

Lady at work....

 

And this is the result after just 10 min of "working".This is going to be our dinner. We traded away our spare sardines for some real fish! 

It took us about 3 hrs to reach Kg Macang Periah , a village just across Kg Bantal. this is where En Noh stays and we were offered either to camp near his house OR stay in his house.

 

We decided to stay a night at Noh's house. After all her wife cooked us a nice dinner with all the fish that was caught on the way home. We were really impressed by the hospitality and the kindness shown by the Noh family. Thank You very much En Noh! 

Next morning we took a "Bot Sewa"..literally a water taxi to Kuala Tahan. kit was another 3 hours of river cruising pleasure!

 

At Kuala Tahan we had arranged Ban Chet to drive my Ford ranger to pick us up.Luch at one of the floating restaurants was great .

CONCLUSION

The Mat Kilau trail is a great trail. On a scale of 5 I would grade the trail as 4.5. it is clean and unspoilt (yet). For future hikers, please keep the cleaniness of the trail. we took out all our rubbish.It is quite a simple trail to hike and the ascend is not so steep. I have included the GPS waypoints for the trip but I would strongly advice the use of a guide as the trail has several sections of undefined tracks.

WE SHALL RETURN TO THIS PARADISE SOON!

 GPS WAYPOINTS

N 04.50667 E 102.91438  Started hiking from here 12 May 2013  1230 hrs
N 04.49591  E 102.91244    1305 hrs
N 04.48772  E102.91389   1335 hrs
N04.48280  E102.90651     1405 hrs
N 04.48211  E102.90340   1425 hrs     Sg Temaka
N04.47820  E102.89943   1512 hrs
N04.48033  E102.89656   1539 hrs
N04.47693  E102.89598     1625 hrs
N04.48112  E102.88708   Camp 1st night
N04.47854  E102.88136   13 May 2013 0845 hrs
N04.47062 E102.86865  1130 hrs    Bukit Main Angin
(Dont confuse with another hill, Gunong Main Angin!)
N04.4777   E102.87850   0920 hrs
N04.4711  E102.97705   1000 hrs
N04.47057  E102.86430  1220 hrs
N04.46667  E102.85754   1305 hrs
N04.46564  E102.84475  1520 hrs Kuala Gemala
N04.44758  E102.81648   14 May 2013 0945 hrs
N 04.47700  E102.65318   1350 hrs
N04.45250  E102.82542  Kuala Chet 1820 hrs
N04.45071   E102.82586  camp 2
N04.44363  E 102.80067 Kuala Lurut
N04.47553   E102.65188  Macang Peria