Corsair Maelstrom Review

Since the Maelstrom Review was done in our old format I thought it would be a good idea to consolidate it all into one post for easier reading.

Design Aspects with Corsair Bikes’ Doug Stuart

I had the opportunity to ask the president of Corsair Bikes, Doug Stuart, a few questions on the Maelstrom. If these explanations don’t make you a believer one ride on the Maelstrom surely will.

Q. What were the main design goals for the Maelstrom?

The overall goal with the Maelstrom was to develop the highest performance Freeride and/or Mini DH bike. As with all the suspension bikes we have developed, three key elements are considered and those are the three things that a rider does on a bike. That is pedaling, coasting and braking. Each of these aspects was considered individually in order to achieve the best performance.

Q. What are the features and benefits of the Maelstrom’s suspension design and what makes it so unique?

When developing a Freeride/Mini-DH suspension concept, coasting is the highest priority to be considered. Coasting occurs when a rider is descending, jumping/landing and cornering. This is the part of riding where suspension performance is most critical. In order to develop the best suspension possible, axle-path is a primary consideration. While most designers create an axle-path based on a bike’s pedaling requirements (normally vertical to forward), Corsair understood and created a design which allowed for a fully rearward moving axle-path. This rearward moving axle-path is achieved by using a ‘mid-high’ pivot location which contributes to the Maelstroms ability to manage square edge hits as well as high frequency inputs from the trail. Furthermore, a rearward axle-path results in a bike maintaining a consistent wheelbase while the suspension manages energy from the trail. In-particular, during 100% suspension compression, most suspension designs cause a shortening of the bikes wheelbase. In the case of the Maelstrom, the bikes two wheels compress in an almost parallel manner thus maintaining the wheelbase in a very critical riding situation.

The other key aspect of the Maelstroms suspension is its true 2:1 leverage ratio. With 7 inches of travel and a 3.5″ stroke shock, the Maelstroms suspension has a superior ability to deal with all aspects of the trail. From its ability to manage high frequency inputs to major hits, the low leverage of the Maelstrom offers superior suspension. Its important to note that the typical spring rate for ‘mid-weight’ riders is a 250 pound spring. This spring not only saves weight, but it also improves the tune-ability of the Maelstroms shock versus other designs which often require spring rates in the 600, 700, 800 pound range.

Finally the Maelstroms suspension design offers a multitude of other benefits; the swingarm is generally short in length which adds to its stiffness and strength, there are no pivots at the rear axle which results in improved swingarm stiffness, the shock is mounted low for a low center of gravity, the shock is actuated by a rocker that rotates around the bottom bracket which creates a very substantial, stiff and strong pivot point, and last but not least, the frames shock mounting position allows for a low stand-over height.

Q. Detail the benefits of the Idler Pulley system.

Whether a rider is using the Maelstrom as a Freeride bike or a Mini DH bike, pedaling efficiency is very important. While freeriders may appreciate pedaling efficiency when they have to ‘climb the mountain’ for an hour or two, DH racers also require pedaling efficiency for acceleration and based on the fact that races are often won and lost by a mere second or two. Efficient pedaling can make a big difference. The Maelstrom introduces two technical aspects to bicycles which have never been seen before. First, the Maelstrom is the first bike to have an idler pulley which allows for multiple front chainrings to be used. And second, the Maelstrom is the first bike to have an idler pulley attached to its swingarm.

While the Maelstroms mid-high pivot creates a rearward axle-path which allows for superior suspension, the challenge that is created is the fact that rearward axle-path creates chain-pull or chain-growth. (sometimes this is referred to as “pedal induced bob”) This is where the Maelstroms idler pulley comes in to play. First, based on the position of the idler pulley, it neutralizes and virtually eliminates chain pull. The result of this is a bike that pedals without any ‘pedal induced bob’. Second, the idler pulley allows for the Maelstrom to pedal with an equal amount of efficiency in any sized chainring. So while many bikes will pedal differently whether the rider is using the middle or small chainring, the Maelstrom pedals the same. In particular, many designs may pedal fine in the middle chainring, but once the rider shifts to the small chainring, the bike may pedal ‘squares’. The Maelstrom does not suffer from this lack of design principle. Finally, as previously stated, the Maelstrom idler pulley is mounted to its swingarm, while pedaling, the chain path actually creates some down-force on the swingarm resulting in a firming of the rear swingarm. The swingarm stays fully active from a suspension perspective, but this firming of the swingarm improves pedaling efficiency.

Q. Why did you choose to use a proprietary headset? What are it’s benefits?

The Corsair headtube is the same size as used for other bikes that use Zero Stack type headsets. Where Corsair deviates from the norm is our headset is a traditional style headset(external cups). This allows Corsair to use an angular contact bearing that is approximately 35% larger than a typical bearing as used in a 1 1/8″ headset. We believe this size bearing is most appropriate for hardcore riding.

Q. What makes the Maelstrom’s tubeset unique?

Corsair uses 6061 tubing. All tubes are custom spec’ed to accommodate our designs. Most noticeable is that fact that Corsair uses square shaped tubes for the top and down tubes. We believe this helps alleviate the tubes being dented under rough and tumble conditions.

Q. What else would you like to tell us about the Maelstrom?

All Corsair Bikes with the exception of the Crown use the same replaceable drop-outs. While the Maelstrom ships stock with 12mm Maxle drop-outs, both 10mm QR as well as Horizontal drop-outs are also available. We believe that a 12mm thru axle is an essential part of getting the most performance out of a hardcore bike like the Maelstrom.

Corsair has put a tremendous amount of work into many small details. The SureLock system provides that all pivot bolts stay tight and correctly adjusted. This same SureLock also makes Corsair Bikes easy to service. All bearings used in Corsair Bikes are either pinch-bolted or clam-shelled. Riders spend a lot of money for their bikes and it is understood that bikes that are ridden hard require regular maintenance in order to achieve the highest performance. The necessity to use hammers, chisels, blow torches or grinders to remove and replace bearings is unacceptable.

The Build

Freeride personified. This one’s all about heading out for an all day ride and getting to the next rock garden, skinny, berm, drop or jump in the fastest, funnest and most reliable way possible. A single 34 tooth ring up front with a wide range 11-32 tooth cassette out back eliminates the need for a front derailleur while still allowing you to earn your way to the top if you have to. If you’re going out for a day that will include more climbing than normal you can slap a 32 tooth ring on the front. On the other hand if you’re lucky enough to have a ski lift or shuttle to do all of the hard work, you may opt for a 36 tooth ring for that extra speed down the mountain. She’s a bit on the heavy side but with the extremely efficient pedaling that the Maelstrom offers you hardly notice and the added reliability of the solid components is reassuring. Some lighter tires, tubes and fork would have this Maelstrom sitting a couple pounds under the 40 mark easily.

• Frame: 2009 Corsair Maelstrom size medium
• Shock: 2009 Marzocchi ROCO WC -or- Elka Stage 5
• Fork: 2009 Marzocchi 66 RC3
• Brakes: Formula Mega, 203mm front, 180mm rear
• Hubs: 2009 Azonic Recoil
• Spokes: 2009 Azonic
• Rims: 2009 Azonic Outlaw ano grey
• Tires: Schwalbe 2.4 Big Betty DH or 2.5 Muddy Mary DH
• Crankset: 2009 RaceFace Atlas FR 170mm
• Pedals: Easton Flatboys
• Cassette: SRAM PG-990 11-32t
• Rear Derailleur: SRAM X.9
• Shifter: SRAM X.9
• Chainguide: e.13 LG1+
• Chain: SRAM PC-991
• Headset: Corsair, +/- 0 degree, proprietary
• Stem: RaceFace D1, 10 deg. rise, 50mm reach
• Bars: TruVativ Holzfeller WC, 15mm rise
• Grips: Lizard Skins Northshore Lock-Ons
• Saddle: SDG Formula FX I-Beam
• Seatpost: SDG Micro Aluminum I-Beam
• Build Weight: 41.1#

Geometry:

Ride Report: The Maelstrom at 7 Springs Bike Park

7Springs was a great way to familiarize myself with the Maelstrom. The trails there are fairly buff and very fast in sections so getting comfortable with higher speeds on the Maelstrom happened pretty quickly. At the risk of sounding cliche, this bike does rail berms but what really sets it apart is its ability to rail berms that are chewed to bits with braking bumps. There’s a short but really gnarly rock garden on the EC1 trail that is new this year. My riding buddy wanted to show it to me so he rolled up the it’s start and pulled over to scope it out. I was feeling good so I decided to just bomb the thing and I’m glad I had the Maelstrom under me. There is no good line through the rocks so I just bee lined and I’m pretty sure I hit all of the biggest rocks along the way. If it wasn’t for the bump devouring rear suspension of the Maelstrom I would have slowed to a point of having to bail. To my surprise the bike actually accelerated through the rocks and kept tracking exactly where I pointed it.

I was surprised with how well the Maelstrom jumps even with the extremely plush rear end. There’s plenty of pop off of the lip and because of the extremely low center-of-gravity it feels stable while in flight. THe low COG also makes it easy to make small adjustments in the air and helps with landings that might not be ideal. The nice thing about the Maelstrom’s true rearward axle path is that you can case a landing and roll away without losing your kidneys. I came into a double a little slow and was ready for the slam and buck of a good hard case but to my surprise the landing felt smooth. I went back to make sure that I did case the jump and I could actually see where my e.13 LG1+’s bash plate hit the top of the jump. That gave me the confidence to hit just about any obstacle in my path.

This trip was the first time I had the Maelstrom out to a true DH bike park and man did I fall in love. I normally try not to get overly excited about a build that I’m reviewing but I can’t contain myself on this one. This is a very special design that should be recognized as one of the best if not the best freeride/mini DH frames ever made. It has geometry and frame dimensions that anyone could feel comfortable with. The ability to run a dual ring with no change in how the suspension reacts to the size of the chainring under hard pedaling is revolutionary. Front and rear axle paths that follow parallel lines of travel to produce a consistent wheelbase under even f/r compression…not only smart but also effective and noticeable out on the trail. It really does just about everything right. The only complaint I’ve heard from other owners and or riders is the additional noise that the idler pulley adds to the drivetrain while pedaling. If this is the only problem that anyone has with this frame I think Corsair has done a great job with the Maelstrom.

Ride Report: The Maelstrom at Snowshoe MTB Park

I’m going to start keeping these ride reports short and to the point with as much media as possible. So, the long and short of it is…the Maelstrom is utterly amazing at a lift served park like Snowshoe. I rode the Pro DH course which had some of the gnarliest terrain available on the mountain and the Maelstrom felt right at home. The rear suspension is extremely active, handling square edged hits with ease and without any hanging up or slowing down at all. Small bump compliance is astounding and big hits are absorbed with a progressive bottomless feel. The rearward axle path, lightweight swingarm, 2:1 leverage ratio and excellent leverage curve harmonize to create a unique system that flat out works as good or in some cases much better than anything currently available. I’ve ridden 10″ travel bikes that didn’t feel this capable through rock gardens.

Here’s a short clip of my first run through the Pro DH course at Snowshoe’s race #2. Everyone was talking about how gnarly the Pro course was so I had to see it myself. I took things slow and I think it actually made it more difficult. The trail crew had outdone themselves with this one.

As I mentioned in the 7Springs ride report, the Maelstrom loves to be launched. Here’s a few clips of two of my favorite trails, Missing Link and Raging Bull.

So once again the neutral geometry and rearward axle path of the back end kept a smile on my face for the whole weekend. With the feeling of greater control I was going faster than ever before and hitting features that I had been reluctant to hit in the past. In spots where I had to pedal I never felt as if I was fighting the suspension to accelerate. The idler pulley system effectively isolates the drivetrain forces from the suspension which allows for the most traction while pedaling over very rough terrain. The drivetrain is noisy but not annoyingly so and the benefits of this configuration far outweigh the noise which is the only drawback in my opinion.

Looking Back…

The immense amount of thought that went into the design of the Maelstrom frame is apparent within the first 50 feet of trail that you ride it on.  It pushes you to go faster and try maneuvers that you weren’t confident in attempting in the past.  It does this all while making you feel completely in control.  I attribute this to the suspension design and it’s ability to smooth out the roughest terrain while keeping a consistent feel to the bike at any level of compression.  The consistent feel is a result of the wheelbase barely changing through the travel due to the fact that the rear wheel is moving at the same angle as the front (rearward axle path).  The overall suspension concept is solid and translates to excellent performance in real world situations.

If I had to nitpick at all I would have to say that I was a bit unhappy with the durability and performance of the idler pulley.  After a few months of riding my chain started to jam between the pulley’s side-plates and the tunnel in the  swingarm that the chain passes through.  This jamming started eating large chunks of material out of the pulley which caused the jamming to occur more frequently.  I replaced the pulley with a new one of the same type but only rode it for a few weeks after installing it and I’m happy to report that the chain didn’t jam with the new pulley.  I am now reading that Corsair has designed a new roller system to replace the pulley.  I would expect the roller to provide improved durability and more trouble free performance.  Other than the pulley problems I did feel that the complex suspension linkage and its placement within the frame left very little clearance for mud shedding and made cleaning a bit of a fuss.  Removing and installing the shock is also difficult because of the placement and small amount of clearance.  The shock (Roco WC) also had to be removed in order to access the air valve for the piggy back chamber.  This placement does however keep the center-of-gravity extremely low as well as allow for the use of a very long stroke shock which results in a desirable true 2:1 leverage ratio.  Compromising clearance and ease of maintenance for improved performance i suppose.

All things considered the Maelstrom’s performance outshines the few nitpicky shortcomings that the owner will have to deal with.  This frame should be within the top three of anyone’s prospective list of freeride/mini-DH frames that one would consider for purchase.

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