Saturday, February 27, 2010

onto the opposite end

this is a 1.5 x 1.5 x 2.25" chunk of aluminum that was cut on the horizontal bandsaw.
i mounted it into the 4 jaw chuck on the lathe to face the ends. very quick and easy compared to using the milling head.
as you can see it yields great results.
up next- the layout. scribing lines and what not using my recently acquired starrett height gauge.

Wednesday, February 24, 2010

one side done

since my practice piece went well, it was time to go for it.

using 'the wiggler' to find approximate center. this is the quick and dirty way, i was not overly concerned with this hole being perfectly centered. for all the other holes though i located them using another much more precise method.

boring, getting very close to the final cut.
i am surprised how accurately the boring head cuts. i measured for my final cut, dialed it in on the boring head and it came out wonderful.
hand tapping on the mill. no power, just using the spindle as a guide. once i got it started to a sufficient depth i used a tap wrench for the rest of the way.
done! now i need to work on a second piece, for the opposite end of the chainstay fixture.

Monday, February 22, 2010

its miller time

in order to complete my 29r mtb frame i decided to re build my original chainstay fixture. before i jump into the deep-end milling the necessary components to the fixture i decided to make a practice piece.

started out with a hunk of 6061 cut on the 4x6 horizontal bandsaw.
squared it up on the mill. pretty rough finish... should have used a larger diameter end mill running at a higher spindle speed.

bored out a 1-1/8" hole using a boring head on the mill. next i would like to try to bore a hole this size chucked up in the 4-jaw on the lathe.

i drilled the pair of holes before i cut it in 2. i cut it using a hack saw, i dont have a large enough diameter slitting saw right now. after i cut it with the hacksaw i cleaned up the faces on the mill. take note of the much nicer finish bc of the larger diam endmill and higher RPM.

through the looking glass

the other side of the lense

Thursday, February 18, 2010

very awesome

IMG_4633, originally uploaded by rackntroll.

meeting at my house for more night XC skiing

Monday, February 15, 2010

Big Red

IMG_4588, originally uploaded by rackntroll.

all together!

Sunday, February 14, 2010

making a p-clamp

dont ask me why, but i felt the need to make some serious p-clamps. these are a bit different than your standard p-clamp.

they use an m4 and m5 bolt. the m4 holds the clamp to the fork leg, and the m5 bolts the rack to the clamp.
doing it this way has a couple nice features. as you tighten a single bolt p-clamp it wants to move, pulling the rack out of place as the p-clamp tabs pull together. the m4 bolt holds the clamp firmly in place so when you tighten the rack bolt it doesnt pull in as it would with single-bolt p-clamp. also you can remove the rack and leave the p-clamp on the bike, already in the proper position to quickly re-install the rack.

this set is made out of 4130, its what i had on hand. its gonna rust if left uncoated. im thinking about re-doing it all out of stainless when i get more metal stock.

its hard to tell in this picture, but there are 7-layers to this clamp.

outer plate
p-clamp tab
cloth bar tape
inner plate
cloth bar tape
p-clamp tab
outer plate

a very solid connection
and of course i spent a couple minutes on the lathe to machine the aluminum spacer!

Saturday, February 13, 2010

build by numbers

remember this post from way-back-when?

after a good long wait, it finally ended up on the bike.
fits perfectly, looks great.

Thursday, February 11, 2010

winter wallop!

IMG_4556, originally uploaded by rackntroll.

rack n roll is closed temporarily, until i feel like shoveling out a path to the barn!

ps- a snow plow is stuck on my road.

Tuesday, February 9, 2010

night XC skiing!

Garmin Connect - XC skiing at night

ahh yes, the trail is starting to get fast, in some sections. other sections have melted leaving exposed grass to slide over.
previously i was under the impression that there is no safe way to go downhill on these things, but i think im starting to get the hang of it.. bend your knees, ankles, keep your hands below you belly button, focus on what each ski is doing and try to make small corrections in ski direction. still not easy, but at least im not duffing it on every downhill now.

i was joined by justin for the 2.16 mi loop, lighting the way was my princeton tec eos which was more than sufficient on medium, justin had some fancier lookin one with a little external battery pack, very cool.

Sunday, February 7, 2010

breaking trail

since my bro-han is living in san diego, he doesnt really have any use for his XC skiis. luckily we wear the same shoe size, boy is that convenient.

XC skiing is really fun. it allowed me to explore sections of the property that are nearly unwalkable any other time of year bc it is so brushy.
this is my neighbors house in the distance. there are 4 houses on the property, all stone, all built under british rule!
coming around the backside of rack n roll HQ.
PS one of the stone farm houses on the property is available for rent, it is a super cool spot. along with the renting the house you get access to 400+ acres to noodle around on, like i did all yesterday!

Thursday, February 4, 2010

decisions decisions

IMG_4523, originally uploaded by rackntroll.

which dropouts to use?!
i cannot tell you the last time i rode a geared mountain bike.
my plans for this bike is to build it up initially with a 2x7 drivetrain for a fun change.
the vertical dropouts will be easier for me to build with, but the thought of not having the ability to run it as a SS scares me.
if i choose to use them, the surly dropout will complicate the process considerably.

Frame No. 2 - 4

next batch of photos, completing the front triangle

head tube prepped, fluxed, ready to tack. using my piece of super fantastic framebuilding re-bar.
tacked, top and bottom.
BB shell, DT and ST prepped. dummy-ing it up to make sure everything still fits.
top tack
bottom tack
checking head tube alignment. i had to move it around some. even with just a couple tacks it takes a lot to get it to move a little.
down tube tacked into place, roughly aligned, top tube and seat tube sleeve prepped. next, disassemble, flux, reassemble, tack, check alignment....
after tacking the TT into place and brazing the ST sleeve, another alignment check, then i could start building fillets. youch, they are still hot!
other side
BB shell
here are the fillets with the flux soaked off

after some finishing work, not trying to go too crazy with finishing the fillets.

Wednesday, February 3, 2010

Frame No. 2 - 3

i started out this next set of steps by making a new tubing block. i havent had the need for a 31.8mm block until now. the only problem was i didnt have a 1-1/4" hole saw. had to use the 1-1/8" hole saw and enlarge the hole with my half round file. got to use my favorite handsaw. its my favorite bc i found it while riding my bike to work about 2 years ago.
ready to do some filing.
down tube to head tube
other end of the down tube.
nice fit on the bottom bracket shell and seat tube.
starting the top tube copes.
roughing out some material with the hack saw. new blades are the best, i had the old blade on for a very long time.
done, both sides.
more wood work. this time needed a big-V to hold the head tube in the vise.
hand facing the head tube, using my fancy new v-block
head tube is ready
drilled the down tube for water bottle bosses.
up next some prep and then tacking the front triangle. oh boy!