11T cassette cog that's *not* an end cog

I don’t think that will work. The spacers will be too thick.

I have some thinner cassette shims to dial in the spacing.

No, I mean the diameter. I think they’ll interfere with the chain.

You wont’ know unless you try, but I’m doubtful.

Maybe contact Fibre-Lyte or similar and have one made out of carbon.

Aren’t you an engineer…to be honest, with all of the things you’re looking at you will likely have to cad it out and got to a machine shop.

Having said that I think the option your looking at has marketability to some. The biggest issue with 1x road is lack of variability for unique situations.

Maurice

Spacers will not hold up to the abuse of a lock ring and will interfere with the chain at 11 tooth diametre.
Just run the double 11 teeth.
The last cog on any cassette usually has a little wider attached spacer, so be aware of total length for full lock nut thread engagement.

Just run two 12 cogs and live with the chainline on the 11

Thanks for the suggestion, though I might find that pretty annoying during the race on faster stretches. Probably better to break out my 62T then so I don’t need the 11T. Need to dive into the data and check how much chain line misalignment is worth in watts before I decide on what to do.

I think bringing out the 62T makes sense. The added weight of not having your custom 58T will most likely be compensated by the reduced drivetrain friction that the bigger chainring, sprocket size and improved chainline brings. Replacing the three biggest sprockets on the spindle of a 11sp Shimano Cassette will leave you with either a 12-21 or a 12-22. If you want a wider range I’d go with a SRAM PG-1170 cassette (11-36), that will give you a range of 12-25.