Surly Grappler Custom Build

Surly Grappler Flat Bar (Custom Build – XS)

One of a kind, built right here at Bicycle Junction.

We’ve taken Surly’s Grappler frameset - their drop-bar trail bike designed for wide tyres and rough roads - and built it up into a playful, confident flat-bar adventure machine. The result is a bike that blurs the line between a capable mountain bike and an easy-rolling bikepacking rig.

This custom XS build keeps the Grappler’s lively, steel-framed feel but dials in a simpler, more upright position for comfort and control. Perfect for smaller riders or anyone wanting an approachable, go-anywhere setup that won’t break the bank.

Build Highlights

• Frame: Surly Grappler (XS) – Chromoly steel, Subterranean Homesick Blue

• Drivetrain: Shimano Essa 1 x 8 

• Wheels: Shimano MT500 27.5" wheelset

• Tyres: WTB Riddler 27.5 × 2.4" – fast-rolling with plenty of grip

• Brakes: Avid mechanical disc brakes – simple, serviceable, reliable

• Saddle: WTB Volt

This setup is built for adventure right out of the gate — whether that’s your first bikepacking trip, a commuter that loves shortcuts through the trails, or a compact mountain bike for exploring Wellington’s backroads and singletrack.

Like every Surly, it’s designed to last, with mounts for racks, bottles and bags when you’re ready to load up. A solid first step into the world of off-road touring, or just a rad all-rounder for weekend missions.

👉 Only one available – XS frame, custom built and ready to roll.