Surly Ogre Rohloff Bikepacking Build

Behold the Surly Ogre in its final boss form.

This custom build came together for Andy’s goal of completing Tour Aotearoa next year, with a simple brief: comfort, reliability, low gearing and a bike that could handle long days with camping gear on board.

The Ogre made sense from the start. It’s not the lightest or flashiest option, but it has the dependable “workhorse” reputation that suits a loaded bikepacking rig perfectly. Tour Aotearoa throws a bit of everything at a bike — gravel, sealed roads, cycle trails, rougher backroads, long climbs and plenty of fully loaded kilometres — so the aim here was to build something sturdy, practical and easy to live with.

At the heart of the build is a Rohloff SPEEDHUB 500/14 with 38:18 gearing. Rohloff is not the cheapest or lightest drivetrain option, but for long-distance touring it makes a lot of sense: sealed, low-maintenance, reliable and able to shift while stopped. The lower 38:18 setup gives Andy a proper loaded climbing gear for steep sections, without chasing unnecessary top speed.

The wheels were built by Wheelworks around a SON 29 dynamo front hub and Rohloff rear. The dynamo powers a Sinewave Beacon 2 light and charger, giving Andy reliable lighting and USB charging for long days on the road.

Comfort was a big part of the brief, especially with Andy wanting to reduce pressure through his hands. We went with a standard Jones H-Bar for multiple hand positions, Ergon grips, high-volume Vittoria Mezcal tyres and a Redshift ShockStop suspension seatpost to take the edge off rough surfaces.

Braking is handled by Shimano XT 4-piston hydraulic brakes, giving plenty of control for a loaded bike on long descents. Andy’s Brooks B17 saddle finishes the build, already being broken in with Tour Aotearoa in mind.

The result is a proper steel adventure bike: Rohloff, SON dynamo, Wheelworks wheels, Jones bar, XT brakes, big tyres and all the practical details that make a bike easier to ride day after day.

Built for Tour Aotearoa, but ready for whatever comes next.

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Build highlights

• Surly Ogre frameset
• Rohloff SPEEDHUB 500/14
• 38:18 gearing
• Wheelworks custom wheelset
• SON 29 dynamo front hub
• Sinewave Cycles Beacon 2 light / charger
• SON rear dynamo light
• Standard Jones H-Bar
• Ergon grips
• Redshift ShockStop suspension seatpost
• Shimano XT 4-piston hydraulic disc brakes
• Vittoria Mezcal tyres
• Brooks B17 saddle

Thinking about a custom bikepacking or touring build? Come and have a chat. We can help with frame choice, gearing, wheels, dynamo lighting, luggage, comfort and all the little details that make a long-distance bike feel right.