Surly Pugsley Review
Although I’ve only had my Surly Pugsley on the road for 6 weeks or so I’ve managed to ride it in a wide variety of conditions - loose deep snow, hard packed snow, ice, paved roads, sandy & rocky beaches, soft desert tracks and rocky mountain bike trails. One of the things holding me back from getting a Pugsley the last few years was that it seemed like such a specialized bike I wondered how I’d justify the cost for a very limited amount of use. I was so wrong. Here’s why…
The Frame
Like the other Surly bikes I own [Long Haul Trucker & Big Dummy] the Pugsley is a well made frame without being excessive in any regard. The tubing is solid double butted 4130 steel. The welds are clean and everything seems well aligned. The powder coat is nice and has resisted many of my attempts to damaged it! I have to say some of Surly’s colour choices have made me wonder what they were thinking. I didn’t love the previous Pugsley colour - Pugnacious Purple, but the grey colour of the current issue Pugsley looks very nice.
When you get down to the details of the Pugsley frame you really appreciate all the thought and crafty design that went into making this bike a reality:
- clearance in back for 3.7″ tires
- rear dropouts offset 17.5mm to the right to allow a normal derailleur room to move the chain around and to clear the massive 3.7″ tires
- 100mm BB shell to move the cranks out far enough to get a good chainline
- the front wheel uses a rear hub so you can swap wheels if the rear packs it in [say the it freezes up you can swap in a fixed gear front and keep moving]
- the front fork is specially offset 17.5mm to match the rear dropouts and since it’s 135mm wide you can get the 3.7″ Endomorph tires in no problem
- the frame has canti-studs and disc tabs so you have a choice of brakes
- full rack mounts
If you want to geek out on this frame I highly recommend you read the Surly Pugsley page.
More important then just having all these features is that they work so well. This is a very unusal frame and is about as non-standard as it gets. However, when you are building and riding it everything just clicks into place. Surly did everything necessary for the bike to perform, but they didn’t add one detail that wasn’t needed - sweet.
The Build
I posted my build details earlier, but I’ll repeat them here as there have been a few changes:
- 18″ 2008 Surly Pugsley frame
- Shimano Alfine hub 21T cog & centerlock disc rotor [160mm] & blue/green non-turn washers
- Shimano Alfine trigger shifter
- Surly 135mm disc SS hub up front w/ 21T Surly track cog [wired on] & Avid 160mm disc rotor
- Surly Large Marge Pugsley offset rims
- Surly Endomorph 3.7″ tires & tubes
- Race Face seatpost 27.2mm
- Selle Anatomica saddle
- Kore stem
- Titec H-bars w/ Ergon grips
- Old Man Mountain Cold Springs rear racks x 2
- Avid BB7 disc brakes & levers
- Phil Wood 100m square taper BB
- Shimano square taper MTB crank w/ 32T chain ring
- NRG thin profile BMX pedals
- Roach stem & TT pad
I wanted to have a solid trouble free bike without blowing the bank. The Shimano Alfine provides a reliable nearly maintenance free drivetrain with an adequate gear range for this bike. I’ve cranked slowly up technical climbs in the low gear and bombed down the highway in the high gear. So far I haven’t wanted or needed more gears. I also must admit I find the uber clean IGH chainline totally sexy. I had intended to use a Nexus 8 twistshifter on this bike, but it wasn’t available when I left for Baja. Having used the Alfine trigger shifter I’m happy with it and don’t plan to make a change.
There are limited 100mm BB options out there at the moment. From what I could tell you either go with a Phil Wood square taper BB, an ISIS BB or the Mr. Whirly external BB/crank from Surly. In my opinion ISIS is not as good a design as the other two options. The Mr. Whirys are very nice, but I didn’t want to bother with any bling on this machine since it was going to get hammered a lot.
I ended up with a Phil Woods BB and Shimano Alivio square taper crank. This is a bomber BB that is completely rebuildable and the Alivio crank is stiff and cheap so I can replace it without sadness when it’s thrashed.
I talked at length about my Large Marge rims & Endomorph tires in a previous blog post so I won’t repeat the whole thing here - I don’t want to put you to sleep! Let me just say these tires/rims are simply amazing. They roll over things like no other wheel set I’ve ever owned. The 29er outer diameter combined with the low pressure high volume rubber is a recipe for ultra traction. I’d go as far as to say the traction limit of these tires is essentially your imagination and courage. If you can just keep the pedals turning these wheels won’t let you down.
I went with Avid BB7s since I had some new ones in my parts bin and they have been proven performers for me. They work well, don’t require a lot of maintenance and are field serviceable should something happen 30kms from the trail head.
I have used a Titec H-bar and Ergon Grips which I really liked on my Big Dummy. You get several comfortable hand positions. I like the wide swept back bars for giving me lots of leverage to move the bike around in technical terrain and I use the forward aero position to stretch out when I’m on a long flat section of the road/trail.
I love the NRG Slabalanche pedals and have posted a review of them already so I’ll just reiterate - they rock.
I used Old Man Mountain racks because I love ‘em on my other bikes and they are the most versatile racks on the market - period. Since I will often be riding the Pugsley without gear I wanted light racks, but when I load up this bike and beat it up I don’t want to have to worry about light racks that are over stressed. The OMM Cold Springs racks combine surprising lightness with bomber performance. I’ve torture tested these racks for years so I was confident they would be a great choice.
Bow Cycle built up the wheels for me and installed the headset. I completed the build at home. I was expecting some drama since it wasn’t going to be a very “normal” bike, but I was surprised how easy it was to throw together. Even the rack installation ended up being fairly easy once I thought it through.
The Ride
The proof is in the pudding as they say…who cares if the Pugsley looks really cool if it doesn’t ride well. Prior to the first ride on my Pugsley I had only taken the NRG demo Pugsley out for a 10 minute spin around Bowness so I had an idea what to expect, but I knew I had a lot to learn. Climbing aboard my new bike first thing that struck me was that it was big…sure it’s a 26er in theory, but the tires are so huge it’s really a 29er. The second thing that struck me was how “normal” it felt to ride. The tires were fairly hard at 18psi and it just rolled along like mountain bike in my downtown neighbourhood. After a few minutes of tooling around to make sure all the vital bits were working I steered it straight for an open field at a local park covered with 5″ of light snow. I’m not sure what I was expecting exactly, but the bike just rolled forward, albeit a bit slower than on hard ground. As long as I kept turning the cranks it kept plowing through the loose snow. Steering was no problem with the wide bars and upright riding position. I had a huge grin on my face as I threw my monster bike into every patch of snow I could find.
The Pugsley’s next test came during a big snowstorm in early December. Naturally with all the snow falling Kurt & I threw some lights on our bikes and hit the streets of downtown. We tried a lower tire pressure to give us better traction and it worked great. The fat tires kept us on course and soaked up a lot roughness from the frozen snow that had fallen earlier in the winter. You can go fast on a Pug if you are willing to hammer the pedals, but these bikes love to cruise. The big wheels keep up your momentum and you can just relax while exploring the world around you. If you want to check something out the Pugsley can take you there whether it’s down a mountain bike trail, through snow/sand. or just down the street. We did find three important limitations for these bikes…1) Endomorphs are better on ice than thin tires, but nothing short of carbide studs is going let you climb or turn hard on a sheet of ice…2) the really greasy snow that has been mechanically disturbed by lots of cars is slippery even for Endomorphs so you have to turn with a bit of caution or the front wheel will wash out…3) if the snow gets really loose & deep a Pugsley will get stuck as 3.7″ tires aren’t snow shoes. That still leaves you a ton of riding potential to exploit.
Next we packed up my truck with the Pugs and some sea kayaks and drove to Baja Mexico for a few weeks of beach biking desert madness. I’ve spent many many months on beaches in Baja. They are beautiful, but the sand and rocks seemed like a bike free zone. Even the desert tracks that are behind the beach are soft with big pools of dust that would be challenging for a normal mountain bike tire. We were a bit tentative when we jumped on the Pugs for our first ride across the beach, but that quickly gave way to a lot of laughing and yelling as we bombed through/over everything we could find. Sand was no problem, loose rocks were no problem and even sections of large rocks were easy to ride across. Tuning the pressure in the Endomorphs was key for good flotation. Too hard and the tires would sink in and wash out or bounce when they hit a rock…too soft and they’d be really sluggish and hard to pedal. We found around 9-11psi to be ideal for most of our riding down there with the front on the low end and the rear on the high end of that range. For paved roads we pumped them up to 15-20psi and they were fast for those times we needed to get someplace fast - like last call at the local bar!
After tackling all the soft loose terrain around our beach camp we started to try stuff that was more traditional mountain biking in nature…technical rocky climbs/descents. We knew the Pugs would be able to get over this terrain, but thought a rigid bike might be a harsh ride. However, the fat tires gave us what felt like a couple inches of suspension. You couldn’t do anything you wanted like on a big travel rig, but if you picked a good line and kept your speed in check the Pugsleys made great mountain bikes. Finally we tried the desert tracks behind our camp. They were windy 4×4 trails that alternated between firm hard pack, loose dust and rocks. The Pugsley were perfect for racing around pretending we were in the Baja 1000. It didn’t really matter if the surface was loose or hard the Endomorphs had us covered.
So no trip or bike is perfect….we did have an issue with flats. Kurt ran over a dead spiny puffer fish on the second day and got quite a few punctures. We patched them, but there were more small ones than we noticed initially so his tires went soft a couple more times. I was getting fed up with this so I suggested we add Slime to his tubes. It was a good concept, but I screwed up the execution. Since we were running Presta valves we couldn’t push Slime through the valves [or so I thought]. I decided to cut a small hole in each tube, squirt in the Slime and then patch it. My theory was that as long as we kept the hole clean of Slime and let the patch vulcanize we should be good to go since the Slime would plug all the small holes he had. What I didn’t realize, since I don’t use Slime in Calgary, is that Slime will de-vulcanize all the patches on your tube. This meant Kurt was destined to fix about 6 flats over again. Eventually we figured out that it was hopeless and threw the Slimed tubes out and just patched any flats we had. Kurt got flats on two occasions and I only got a flat on the last day [another puffer fish!] - not bad for biking in the desert. I have since learned of a way to get Slime into Presta tubes without cutting them and we may try this on our next desert trip since I think Slime would have fixed all the punctures we had.
Once back from Baja we have been out to Fishcreek for some frozen trail riding. It’s hard to believe how well those fat tires rock on snow covered trails. As long as we kept the cranks going round we were cruising over logs, up steep techy climbs and bombing back down. You do have to manage to your weight distribution just like on a regular mountain bike so the rear wheel doesn’t spin out, but that’s to be expected.
One other thing that takes some getting used to is at lower pressures if you ride the Endomorphs on a high traction surface - say on a paved road between trails - the bike pulls left & right as it grips different areas on the road. It’s not a huge problem and it can be resolved by adding some air to the tires, but we often just deal if we know we’ll be on something loose again soon. As all new Pugsley owners soon learn - adjusting tire pressure to suit the terrain is the key for a fun ride.
The Future
So what’s up for the Pugsleys now that we are back in the Great White North? Well definitely more trail riding - hopefully when it’s above -20 deg C! Kurt is commuting to work on his Pug. We live in the same apartment building downtown so we’ll be riding the core when we don’t have enough time to head further afield. I’m keen to take the Pugs up to Canmore/Banff and try some serious mountain bike trails in winter.
As far as the bikes themselves go we are pretty happy with how everything is working and I don’t think we’ll be messing with a successful build. Kurt is going to add some OMM racks and get some panniers so he can tour on his Pugsley come summer. I’m going to work on some coroplast fenders to keep us and our bikes a bit cleaner - I’ll post something if I get a good result.
Speaking of summer - we don’t plan on hanging up the Pugs when the snow melts. For goofing around they are the most fun mountain bikes we’ve ever ridden so I see some weekend urban assault action happening downtown. We are also thinking of riding them on the trails up in the mountains so we can compare how they perform with a normal hardtail or FS mountain bike. Good times for sure!
One Pug to Rule them all!
I opened this review talking about how versatile the Pugsley is and I wanted to close by listing some obvious bike missions you could use the Pugsley for - it truly is a bike that can do almost anything:
In stock trim:
- snow biking - that’s obvious
- beach/desert biking - pretty obvious as well
- trail riding - it makes a great mountain bike rigid with Endomorphs at low pressure [say 8psi]
Add a 29er wheel set with various tires and it can be:
- a 29er MTB - rigid or with a 29er suspension fork [like the Fox F29] and some 29er knobbies
- a commuter bike - add some 29er Schwalbe Big Apples
- a touring bike - add some 29er Schwalbe Marathon XRs
- an ice bike with some studded tires like the Schwalbe Ice Spiker
Add a trailer and it’s your utility bike.
You can run it as a:
- single speed
- fixed gear
- derailleur multi-gear
- internal hub multi-gear
I can’t think of another bike that can do all this at anything close to this price.
If you want to see more of my Pugsley photos click here.














































