Innovating the Trail Building Toolkit: The Story of the Terracotta
One of my favorite tools for shaping loose dirt is called a "concrete placer." Have you ever heard of it? That's okay if you haven't because most people have probably never even seen one before. However, they're available at most big-name hardware stores. Originally designed for concrete workers to move wet concrete into place, it surprisingly works great with loose dirt too! I stumbled upon it when a landscaper praised the tool so much that he gave me one just so I could try it. Needless to say, I fell in love with it too!
Unfortunately, during one of the trail builds I volunteered for with Sorba-CSRA, about seven of our hand tools, including my trusty ol' Concrete Placer, were stolen from the trail. As I stood in Lowe's (a local home improvement store) with a brand new concrete placer in hand, I reflected on all the times I had to haul multiple hand tools in and out of the trail for workdays. This got me thinking, and I began researching trail tools, specifically multi-functioning tools that would eliminate the need for carrying so many different ones.
In my search, I came across a well-known tool in this category called the Rogue 70AR, also known as the "Travis Tool." It combines a hoe, pick, rake, and scraper into one tool. I immediately purchased it, but I was disappointed by the ineffectiveness of the rake edge. As someone who loves using both the bow-rake and concrete placer on loose dirt, the 70AR just didn't cut it. It's a great little hoe, lightweight, and you can still do some raking with the few teeth it has, but I knew it could be better.
This is where my basic knowledge of Fusion 360, a 3D CAD software, came into play. I spent hours after work every day sketching up several different ideas, tweaking them bit by bit. I considered factors like weight, balance, functionality, handle placement, strength, ergonomics, and if possible, aesthetics! I also wanted to incorporate a curve in the tool to match the diameter of a person's swing, making the cutting slightly more efficient and enabling excellent tamping in berms.
After several weeks, I finally settled on a design. Now it was time for prototyping! Unfortunately, I didn't have the space or funds to invest in all the necessary equipment myself, so I reached out to a friend in my hometown who owns a custom fab shop. He was able to cut the parts from 1/4" mild steel and have them shipped within a few days!
I spent a few weeks with this tool, taking it out on the trail for myself and others to try during our builds. This thing was an absolute beast! It did everything I wanted and more. However, the weight was extremely fatiguing, weighing about 2850g with the handle. I could only use it for a few minutes at a time before needing a break. But the concept was proven, and I was very pleased with the results. I just needed to shed some weight.
I named the tool "The Champions Mattock" since most of the trail champions in my area prefer mattocks as their tool of choice. This new design of mine was essentially a mattock but with a rake on the side, making it even more versatile.
At this point, I started reaching out to companies that specialize in tools for mountain bike trail builders. I contacted several different companies, but either didn't hear back from them or they were too busy to take on a new project. Then, someone on social media suggested a company called Up.Bike, which I hadn't heard of yet. I thought, "Why not?" and sent them an email in December. To my delight, Dan responded within a day, and our communication began.
Several more weeks went by with back-and-forth emails, some even left without a response. Then, on February 15, 2023, I received an email out of the blue from Dan asking for my address, along with a few attached images. I cannot express how stoked I was when I opened the images and saw the Champions Mattock professionally made from A400 hardened steel, gleaming with rainbow patterns from the heat treatment process. It was a thing of beauty!
At this point, the tool became available for purchase on the Up.Bike website under the name "Terracotta."
When I finally held the tool in my hands, I was ecstatic to feel how much lighter it was. It weighed only 1979g compared to the 2850g prototype. We achieved this by using thinner 3/16" material and eliminating the triangular braces, thanks to the hardened A400 material.
I donated four of these tools to various mountain bike clubs and one to a professional trail-building company for feedback. I initially thought that professional trail builders wouldn't find this tool useful since they typically have equipment and access to specific tools that work best for a particular job. However, to my surprise, the feedback was great. The main thing they loved about it was that they didn't have to keep changing tools. While certain tools might be better suited for specific tasks, having to constantly drop one tool, walk several feet to grab another, use it briefly, and then drop it again to return to the first tool can become quite annoying after a while.
In conclusion, the journey from discovering the versatility of a concrete placer to designing and bringing to life the Champions Mattock has been an incredible adventure. Through research, prototyping, and collaboration with Up.Bike, and valuable feedback from trail builders, this tool has evolved into the Terracotta, a beautifully crafted and lightweight companion for trail champions and trail enthusiasts alike. With its multifunctional design and the convenience of eliminating the constant tool swapping, maintaining trails has become more efficient and enjoyable. The Terracotta stands as a testament to the passion and dedication of trail champions and serves as a powerful tool to ensure the preservation and enhancement of our beloved trails for future generations to enjoy.
Words: Josh Dexter Photos: Josh Dexter
ABOUT THE AUTHOR
Josh Dexter
Meet Josh, a true 'Jack of all trades'—skydiver, FPV pilot, mountain biker, photographer, designer, and builder. After 30 years in Florida, he now resides in South Carolina, closer to the mountains, where he dedicates his free time to building and maintaining mountain bike trails for the CSRA region alongside running his family-owned cafe.
