Mountain Cog

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Brakes are one of those things most riders don't think about until something goes wrong — and then it's all they can think about. This episode of Mountain Cog changes that. Josh and Dane dig into the Hayes versus Shimano debate with the kind of depth and honesty that's hard to find when every other review online is either sponsored content or a five-minute YouTube video that barely scratches the surface. The conversation starts with a simple real-world observation from the trail and quickly evolves into something genuinely eye-opening about how these two systems ar...

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Sunglasses might be the most under-thought of piece of gear in mountain biking. Most riders either skip them entirely or default to whatever they already own, without knowing that the wrong tint, frame, or fit can actually make riding harder and riskier. Rob Tavakoli, CEO of SportRX and a guy who's been obsessed with eyewear since he was nine years old, joined the Mountain Cog crew in Tucson for a follow-up to his Episode 71 appearance — and this time he brought a bag full of frames to show and tell.

Rob and th...

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When Josh Sprague couldn't find a hydration pack that stayed put, ran cool, and didn't feel like dead weight on his back, he built one himself. Fourteen years later, Orange Mud offers unique solutions to the endurance and mountain bike markets. Sprague joins Josh & Dane this week to explain what makes Orange Mud's Endurance Pack different from everything else on the market. The conversation covers pack geometry, upper-back placement, heat release through open side construction, and why he's convinced that waist packs — no matter how trendy — will never be the answer for serious trai...

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Ever wonder why bike shops seem to come and go? The answer's in the math, and it's not pretty. Josh dives deep into industry data from the National Bicycle Dealer Association, trade publications, and financial modeling sites to paint a realistic picture of bike shop profitability. Spoiler alert: the average bike shop owner in America takes home less than $50k a year and works 50-60 hours a week. With 1,000's of bike shops operating nationwide and razor-thin margins on everything from components to complete bikes, staying in business is more about passion than...

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Does your mountain bike fork feel harsh over bumps? Is your suspension bottoming out on drops or packing down in rock gardens? In this comprehensive suspension setup guide, professional bike shop owner and suspension expert Dane Higgins and co-host Josh walks you through the exact process to dial in your MTB suspension settings. Starting with proper sag measurement (the foundation of all suspension tuning), you’ll learn how to use a shock pump, set the correct air pressure for your weight, and understand why sag percentages vary between 120mm XC forks and 180mm DH...

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New to mountain biking in 2026? This beginner-focused episode delivers expert guidance on every aspect of starting your mountain bike journey. Learn the key differences between entry-level hardtail bikes (under $1,000) and full suspension options (around $2,000), plus how to determine the right frame size based on your height. Discover why bike shop quality brands like Trek, Giant, Specialized, Norco, and Rocky Mountain offer better long-term value than department store alternatives, and get insider tips on buying used bikes safely, including why 2020 or newer models feature better geometry.

Safety and preparation are crucial for...

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Mountain bike enthusiasts get real-world product testing results in this Bike Shop Secrets episode featuring comprehensive reviews of the Norco Optic and Outbound bike lights. Dane provides an 8-month review of his Norco Optic, a unique 125mm travel bike with high pivot suspension design featuring a rearward axle path and idler pulley system. He explains how this unconventional setup delivers exceptional smoothness on technical, rocky terrain while maintaining pedaling efficiency. Josh shares his year-long experience with Outbound Lights' Trail Evo and Hangover models, discussing light quality, durability, mounting systems, and why the cutoff...

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Looking to upgrade your mountain bike's contact points without breaking the bank? This episode of the Mountain Cog Podcast explores two of the best grip solutions for combating arm pump and hand numbness: SQ Labs 70x 2.0 Pro Grips and Rev Grips. SQ Labs brings German precision engineering with ergonomic design focused on reducing peak loads and delaying forearm fatigue through advanced TPE compound technology. Josh details his experience running these $40 grips across multiple bikes and why he's convinced enough to replace every grip in his stable. Meanwhile, Rev Grips offers a unique suspension...

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Starting a product company in the cycling industry isn't for the faint of heart—just ask Ryan Burney. After years of designing bikes at Cannondale and GT, Ryan quit his job with no safety net to launch Rim Saver and eventually Bare Innovation, his engineering consulting firm. In this episode, Ryan gets real about the economics of running a small cycling business, why he realized product companies need to "go big" to survive, and how he pivoted to consulting while still growing his tire insert brand. His story offers valuable lessons for anyone dr...

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What killed the direct-to-consumer bike boom? This episode combines financial data, industry research, and insider knowledge to explain the DTC mountain bike industry's spectacular rise and dramatic fall. Josh presents findings indicating that many of the DTC bike brands are financially struggling or insolvent. The podcast reveals how customer acquisition costs skyrocketed 200%+ over ~10 years as Meta and Google replaced traditional retailers as profit-extracting middlemen, while increased competition, privacy changes, and expensive venture capital made the DTC model financially unviable for most DTC companies.

Listeners get unprecedented insight into the financial health...

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Discover how the Verde Valley Cyclists Coalition built one of Arizona's most successful mountain bike trail networks in this episode featuring VVCC President Tracy Randall and board member Lars Romig. From Sedona's iconic red rock terrain to the emerging systems at Dead Horse and Blowout, learn how this advocacy group transformed contentious Forest Service relationships into productive partnerships that have created over 500 miles of mountain bike trails. Tracy and Lars share their journey from illegal trail building in the early 2000s to becoming a model for community-driven trail development, including their work on...

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Are you struggling with a mysterious bike creak that's driving you insane? In this episode of Mountain Cog Podcast, hosts Josh and Dane dive deep into the most frustrating problem in bike maintenance: diagnosing and fixing bike creaks. Learn the systematic approach mechanics use to troubleshoot creaking sounds, from checking your headset and wheel axles to inspecting bottom brackets, pedals, and suspension pivots. Dane shares insider knowledge on the most common culprits behind bike creaks and reveals why some noises seem impossible to locate, even for professional mechanics.

The conversation also...

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Thinking about swapping your mountain bike frame but wondering if your existing components will transfer over? This comprehensive bike shop secrets episode dives deep into frame compatibility with industry expert Dane Higgins. Learn about critical measurements including rear hub spacing (boost vs. super boost), headset configurations, fork steerer tube length, and bottom bracket standards. The hosts cover everything from dropper post insertion depth and seat collar sizing to disc brake adapter requirements and chainline adjustments for different rear-end widths.

Whether you're considering a frame-only purchase from brands like Revel or Intense...

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When your local bike shop orders parts, there's a complex supply chain working behind the scenes that most cyclists never consider. Quality Bicycle Products (QBP) operates as the invisible backbone of bicycle retail, distributing products from four strategically located warehouses to over 5,500 independent bike shops. QBP sales rep Bryce Buckner reveals how this system works, explaining why bike shops choose QBP over direct manufacturer relationships and how bulk purchasing power translates to better pricing and faster shipping for consumers.

The discussion explores QBP's house brands that have become cycling icons: Salsa's...

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In this thorough mountain bike gear review episode, hosts Josh and Dane share their honest, long-term testing experiences with popular MTB products including SportRX Huckson Sunglasses and Vittoria Agarro Tires & Inserts. The discussion covers detailed performance analysis of Vittoria's graphene-enhanced tire compounds, weight comparisons between different tire and insert combinations, and practical advice for desert mountain biking conditions. Josh provides an 18-month review of SportRX Huckson glasses, explaining why they've become his go-to choice for mountain bike eyewear over popular brands like Oakley and Smith.

Dane delivers an in-depth first ride...

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Experience the diverse mountain biking terrain of Southwest Colorado with Jake Quigley, owner and operator of Zuma Bike Ranch in Cortez, Colorado. Strategically located at the northern part of Phil's World's expansive 62-mile trail network, this 40-acre mountain bike facility provides riders with direct trail access from their campsite. The unique location offers incredible variety, from high desert pinyon and juniper riding to technical canyon descents, with Durango and Telluride's alpine adventures just an hour away.

Jake shares his journey from outdoor industry professional to ranch owner, creating a comprehensive mountain...

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Discover the engineering and chemistry behind tubeless technology and more with Stan's (NoTubes) President Mike Bush, whose industrial manufacturing background shaped ~25 years of cycling innovation. Bush explains the technical details of bead seat geometry, the science of sealant particulate systems, and how CT scans of mounted tires revealed the "bead float" phenomenon that caused early tubeless failures. Learn about the development of ExoCor valves designed to address sealant compatibility issues with traditional Presta valves, the chemical reaction that makes Dart puncture plugs work instantly with Stan's sealant, and the biodegradable formulation using natural...

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Rider safety takes precedence in this essential bike shop secrets episode, where bike industry veteran Dane Higgins addresses the critical question every mountain biker faces after a crash or component failure: "Can I ride it?" Learn the definitive protocols for assessing carbon frame damage, from the professional coin tap test to identifying dangerous stress points that require immediate replacement versus repairable damage. Understanding the difference between cosmetic carbon scratches and structural compromise can literally be life-saving, especially when dealing with handlebars, steerer tubes, and other critical load-bearing components.

Mechanical reliability directly...

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Tired managing batteries, firmware updates, and paying for expensive electronic drivetrains? This episode with SRAM's Jimmy Nordloh goes deep into the new Eagle 90 and Eagle 70 mechanical transmission systems that deliver transmission's shifting performance without electronic complexity.  The new mechanical transmission uses the same cassettes and flattop chains as the wireless transmission systems but use a traditional cable. At ~$670 and ~$490 respectively, these systems are for riders who want transmission performance without the heavy price tags, apps, or batteries.

SRAM has also standardized on mineral oil across their entire brake range (including the n...

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In this comprehensive bike maintenance episode, suspension expert Dane "Suspension Guru" Higgins tackles the most common disc brake problems plaguing mountain bikers. Learn why your hydraulic disc brakes keep squealing despite new rotors and pads, how brake pad contamination occurs, and the proper bedding process for noise-free performance. Dane explains caliper alignment techniques, the debate between OEM vs aftermarket brake pads, and why sanding contaminated pads often fails to solve squealing issues.

The episode also covers essential suspension service knowledge including the difference between lower and full fork services, typical service...

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In this comprehensive deep dive, Shimano's Mountain Bike Product Manager Nick Murdick reveals a copious amount of details about their new XTR M9200 Di2 wireless groupset. Learn how Shimano engineered their first fully wireless mountain bike drivetrain with on-board derailleur batteries, customizable shifter paddles, and rock-impact protection designed from "the rock's perspective." Murdick explains the technical innovations behind the wedge-shaped derailleur design, dual-click shifting mechanism, and why Shimano chose derailleur hangers over direct-mount systems for maximum trail durability.

Discover the complete XTR M9200 component lineup including new brake technology with updated...

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Go inside Park Tool, the world's largest bicycle tool company, with Technical Expert Truman Purdy in this deep-dive interview. Learn the fascinating origin story of how Art Engstrom and Howard Hawkins transformed from a small Schwinn repair shop in Minnesota to creating the iconic blue tools that define professional bike maintenance today. Discover why Park Tool switched from red Schwinn-branded tools to their trademark blue color, how they protect their brand identity, and the surprising business decisions that built their global dominance in bicycle tool manufacturing.

Truman reveals exciting details about...

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This engaging episode features the Calirado Kid, whose authentic and humorous mountain biking videos have built him a substantial following with videos regularly reaching hundreds of thousands viewers. While he shares interesting glimpses into creating his popular videos, the conversation primarily delivers valuable insights from his extensive riding experiences across Arizona's technical terrain, Colorado's epic mountains, and Northern California's diverse trails. Mountain biking enthusiasts will appreciate his detailed analysis of what makes southwest trails distinctive with their challenging rocky features, technical climbs, and rewarding descents like Bug Springs which he describes as "just...

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In this in-depth episode of the MTNCOG Podcast, we dive into the science behind mountain bike tire design with Ken Avery, Senior Vice President of Product Development at Vittoria. Ken breaks down the complex process of tire manufacturing, from the initial casing construction using nylon or cotton materials to the vulcanization process where the tread is applied. He explains how Vittoria's innovative use of graphene technology creates tires that both roll faster and grip better than competitors, challenging common misconceptions about tire compounds and performance.

The conversation explores Vittoria's progressive sipe...

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In this engaging episode of the MTNCOG Podcast, the hosts welcome Jess the Maker, a prominent mountain biking content creator who blends humor, authenticity, and technical riding expertise. The episode was recorded shortly after Jess was in town working on a project with 'Visit Tucson'.  The conversation explores how she's helping showcase Tucson as a "hidden gem" of mountain biking while also discussing her experiences in renowned destinations like Whistler, Vermont, and Bentonville. Jess shares insights about her Specialized bike collection, including her Stumpjumper and newly acquired Levo 4, and her preferences f...

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In this episode of The MCP, hosts Josh and Dane dive deep into the science of mountain bike suspension with Norco development engineers Colin Ryan and Kirk McDowall. The conversation explores Norco's different suspension platforms with detailed explanations of axle path, anti-squat, and anti-rise properties. The engineers reveal how these technical elements directly impact riding performance, particularly in technical terrain with square-edge hits and rock gardens.

The discussion also highlights Norco's innovative RideAlign bike setup system, which uses rider metrics to provide personalized suspension, cockpit, and tire pressure recommendations. Kirk and...

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In this unfiltered episode of The Mountain Cog Podcast (recorded during the snowy Sedona Mountain Bike Festival) hosts Josh and Dane are joined by special guests Mike "Babyfoot" Jones and Derrick Kampfer for a raw, technical dive into mountain bike suspension. The conversation takes unexpected turns from the hilarious origins of "nipple management" in bike maintenance to detailed comparisons between Fox, DVO, and RockShox fork technologies, with expert insights on how suspension choice impacts ride feel and performance on different trails.

The episode explores the technical aspects of mountain biking while...

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The Mountain Cog Podcast welcomes Julian Richardson, Lead Industrial Designer at Faction Bike Studio, for an in-depth exploration of bicycle design. Julian explains how Faction operates as design consultants for bike manufacturers, handling everything from initial sketches to final production support. The discussion clarifies the often misunderstood difference between industrial design (focused on user experience and aesthetics) and  engineering (focused on developing and validating the functional, structural, and kinematic elements), while detailing their collaborative process that transforms concepts into rideable products.

The episode covers crucial industry topics including the challenges of m...

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In this information-packed episode of Mountain Cog, hosts Josh and Dane dive into essential mountain bike maintenance tips that every rider should know. They share their expertise on cutting carbon handlebars safely using abrasive blades, explaining how to prevent fraying and properly finish the cut edges. The conversation then shifts to the benefits of Squirt chain wax for desert riding conditions, with both hosts sharing their personal experiences and highlighting why proper application makes all the difference.

The episode continues with valuable insights on bike modifications, including the importance of changing...

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The latest episode of The Mountain Cog Podcast features an in-depth discussion with Ruth Cañamar from the Sonoran Desert Mountain Bicyclists (SDMB) about transforming Tucson's mountain biking landscape through community-driven initiatives. The conversation highlights the successful recent Poker Ride event, which brought together various cycling groups, bike shops, and community members for a day of non-competitive riding and socializing at Tucson Mountain Park, demonstrating the power of inclusive community events in mountain biking.

Ruth shares her personal journey into mountain biking and her role in expanding SDMB's reach t...

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This episode delivers an expert comparison of leading electronic suspension systems, featuring Mountain Cog host and suspension specialist Dane Higgins' detailed analysis of SRAM Rockshox Flight Attendant, Fox Live Valve, and Fox Live Valve Neo. The discussion examines how each system approaches terrain detection and suspension adjustment, with Flight Attendant's cross-country focus contrasting with Neo's gravity-oriented design. Installation requirements, compatibility considerations, and real-world performance characteristics are thoroughly explored.

Pricing and value propositions also take center stage, with systems ranging from $1,400 to $3,500 depending on configuration. The hosts provide valuable insights into how...

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In this episode, we sit down with Jimmy Nordloh, SRAM Field Guide for the Southwest region, to explore the evolution and innovation behind one of mountain biking's leading component manufacturers. Jimmy shares insights into SRAM's brand portfolio including RockShox, Zipp, Truvativ, Quark, Time Pedals, and Hammerhead, explaining how SRAM has grown through strategic acquisitions while maintaining quality across their product lines. Listeners will gain valuable perspective on the differences between SRAM and Shimano components, with particular focus on serviceability and compatibility.

The conversation delves into technical discussions about SRAM's breakthrough products...

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In this captivating episode, we sit down with Tim March, the ghost writer behind Steve Peat's autobiography "Forged by Speed: The Making of a Mountain Bike World Champion." March reveals the three-year journey of bringing mountain biking legend Steve Peat's story to life, drawing from over 20 years of detailed personal diaries and 100+ hours of recorded conversations. Listeners will discover how Peat balanced his notorious party lifestyle with becoming one of downhill mountain biking's greatest champions.

The conversation explores Peat's evolution from riding rigid bikes on Sheffield's gnarly terrain to...

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Josh and Dane from The Mountain Cog podcast dive deep with Adam Robbins from Faction Bike Studio, uncovering how this secretive Quebec-based engineering firm shapes the mountain bike industry. Since 2010, Faction has operated as the only bike-specific design and engineering studio globally, helping brands of all sizes create innovative products while staying deliberately behind the scenes. Adam explains their comprehensive approach to bike design, from industrial design and prototyping to manufacturing support and FEA (Finite Element Analysis), revealing how Faction maintains their clients' spotlight while perfecting designs.

The discussion highlights Faction's...

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In this episode, we sit down with Tom "Danger" Place, co-owner of Outbound Lighting, a Chicago-based manufacturer revolutionizing bike lights through innovative engineering. Tom shares the company's origin story, how he partnered with founder Matt, and explains their unique approach to bike light design that prioritizes beam pattern over raw lumens. Listeners will learn why Outbound places wider, more powerful lights on handlebars and spot beams on helmets—the opposite of traditional setups.

The conversation explores Outbound's design philosophy, manufacturing process, and how their small team of six produces te...

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Episode 88 celebrates Dane's 25th episode and features an in-depth discussion between shop owner Dane and rider Josh about the pros and cons of electronic bike components versus traditional mechanical systems. The hosts examine the substantial price difference between electronic and mechanical groupsets – with electronic options typically costing twice as much – while breaking down exactly what riders get for their investment. From SRAM's wireless transmission systems to Shimano's Di2 technology, the episode covers how electronic shifting provides more precise gear changes, eliminates cable degradation issues, and significantly improves shift quality under load.

Desp...

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Chris Johnson of Tonto Gravity Riders (TGR) joins us to discuss how this grassroots organization evolved from building unauthorized jump lines to becoming a trusted Forest Service partner maintaining and developing trail systems across Arizona. The episode traces TGR's origins around 2010 and their work legitimizing the legendary NRA Pit jump spot before focusing on creating gravity-oriented trails in the Pinal Mountains. Chris explains how their dedication to quality trail building and community focus transformed what began as "rogue" building into award-winning stewardship.

The conversation highlights TGR's recent work at Sunrise Ski...

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Episode 086 takes listeners inside Tucson Hop Shop, a craft beer destination that's become synonymous with cycling culture in Southern Arizona. Owner Jessie Jean Mance and Sarita Mendez join hosts Josh and Dane to discuss how their business evolved into a cyclist sanctuary, complete with bike racks, a welcoming outdoor courtyard, and a business philosophy centered on community building rather than just selling beer. The conversation highlights how the shop's strategic location near major bike trails and their deliberate focus on cyclist-friendly amenities have created a thriving establishment where riders gather before, during, and...

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Discover the remarkable story behind Mt. Lemmon's mountain biking trail network as Josh and Dane interview TORCA's leadership team. President Nick Giovannucci and Vice President Matt Hrabko provide an insider's look at the specialized techniques and challenges involved in building sustainable mountain bike trails across Southern Arizona's iconic desert sky island, where dramatic elevation changes create one of North America's most diverse riding environments.

This information-packed episode explores TORCA's innovative approach to trail design and maintenance in challenging desert terrain, their collaborative work with government agencies and environmental stakeholders, and their...

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The Mountain Cog podcast features an in-depth conversation with bike industry veteran Carlos Quintero in episode 084. Currently working as Southwest Market Manager for Enso Sales Group, Carlos reveals the economic fundamentals of bike shops, explaining why accessories provide significantly higher profit margins compared to actual bike sales. The discussion tracks his career journey from bike shop manager at Bicycle Warehouse to inside sales roles at Giant and Specialized, offering unique perspectives on how these major manufacturers approach the market differently.

The hosts and Carlos explore the post-pandemic changes in the mountain...