Wednesday, April 29, 2009


this was REALLY hard.
the BB shell soaks up sooooo much heat, finding the correct balance between heating the shell and the thin walls of the tubing was quite challenging.

chainstay fixture

started out as my fork fixture, but made an accessory so it can double as a chainstay fixture.
different BB drops can be set by changing the clamping location on the seat tube.
in the top picture you can also see the chainstay dimple i added to give sufficient tire clearance.

Tuesday, April 28, 2009


dropouts in the chainstays
now i just need to figure out how to jig them up to the BB, and accurately set the BB drop.

Friday, April 24, 2009

front triangle

done (minus a couple braze-ons)

TT coped and fit.
this was my second top-tube. the first one got nibbled a little too short trying to attain that perfect fit. oh well, into the "too short" pile. no worries though, it will get re-used.

dont touch, still hot. very hot. we will see how good these are after soaking off the flux and finishing them.

this one almost makes it look like i know what im doing!

so heres the nitty-gritty so far...

somehow things shortened up. the TT ended up being about 1cm shorter than the drawing.

botched the DT/BB. i had it tacked (4 tacks) and on the alignment table cold setting the HT into the same plane as the ST. the tacks popped. im guessing they didnt penetrate enough, or the amount of cold setting was too great. i dunno, either way i was pissed!

so i cleaned things up a bit and layed down a full fillet. during that process there was a bit of overheating of the DT here and there.

once i had that done then i needed to cold-set it to remove some HT twist. wow, i cant believe how much i had to lean on that sucker to get it aligned. no wonder the alignment table came with a massively long heavy cheater bar.

i am really kind of glad things went the way they did. i learned a few things so hopefully frame #2 will go a little smoother, and because i put that DT/BB through hell and had to cold set the heck out of things it will really give me a feel for how much BS the metal can withstand before it leads to premature failure. the only stipulation there is that i will need to ride this frame a lot to see if i can get it to fail. that may be the hard part!

Wednesday, April 22, 2009

Tuesday, April 21, 2009

new goody

have the dynohub, just got the headlight. now all i need is the rims and spokes.

Friday, April 17, 2009

urban bike

taking a trip into philadelphia this weekend to deliver the ute.
laura definitely needed some sort of cool urban transportation to get around, so i set up this cute little ride for her.

Thursday, April 16, 2009


double cope on the DT
rear kona ute rack

front kona ute rack

hes a fattie
lets face it

Wednesday, April 15, 2009

this time its for real

that right folks, this is my actual headtube and downtube. frame number naught-naught-ONE is officially under construction.

Monday, April 13, 2009

drop-outs and fender mods

wouldnt it make more sense to call them hold-ins? i mean seriously, they're doing a lot more holding-in than dropping-out!

the latest installment of fender modification. will get it powdercoated at some point. thinking about getting the stays powdercoated also, but not quite sure yet... any opinions?

back on topic

hopefully now that i finally got my alignment table set up, and my ghetto fork fixture built, i can turn this into a fork-like-item.

waiting out the rain

stuck inside on sat, just waiting for the rain to dwindle.

i took that opportunity to transform our industrial grey filing cabinet into wood.
after a few hours the rain stopped. so we brought our drinks out to the ponds.

i caught a tree, precariously balanced, trying not to go for a swim.
still fighting the tree
momma and poppa goose. shes been on those eggs for over a week now.
first fish of the season. all i caught was some trees.

Friday, April 10, 2009

my new fork/chainstay fixture

the last rack for the kona ute used up ALL of my rack tubing. somewhere around 70ft of tubing went into that!!!

so without any racks to work on, i took the opportunity to build my fork/chainstay tacking fixture that has been on the drawing board for a while.

i plan to tack the fork in this ghetto fixture, then alignment of the fork will be checked post tack on my bringheli alignment table, then i should be able to finish brazing it out of the fixture.

bc i plan to build my frame jigless, this will also double as a fixture to hold my chainstays in place for tacking. i will need to make some accessory for it to clamp it to the BB shell on a completed front triangle. ill do that when necessary!

Tuesday, April 7, 2009

un grande rejilla

starting out as some sub-assemblies
unusual jigature for tacking
was in the zone, nailed this cope perfectly on the first try.
one of many test fittings. i must have installed and removed this thing about a 1000 times throughout the course of the construction.
basic framework done, but a lot more criss-crossing to go.
front and rear for a kone ute.
dont study it too hard, you may get a headache.
at the powdercoater now. more detailed pics a'comin.