Tuesday, March 30, 2010

Frame No. 2 - 11 - dropout replacement

was not happy with the way the rear triangle turned out, so i decided to cut out the drive side dropout, make a new one, and braze it into place.

started by drilling and tapping a piece of mild steel to receive a derailleur.

after some drilling, cutting, hacking, filing...

bye bye dropout

getting close, still need to shape the dropout some more, still pretty fugly at this point.
one thing i may have neglected is clearance for small cogs if i choose to run it geared...ill worry about that later though!

Sunday, March 28, 2010

Frame No. 2 - 10

all of the major construction is complete.
just need to clean up the remaining joints, prep it, sand it, paint it, build it, ride it.

Wednesday, March 24, 2010

making sundry items on the lathe

jesse and the girls came to visit, i added some water bottle mounts to the rack i made for his kona ute.

i set aside 4 bottle braze-ons for his rack, some how i lost one. so i made one for him on the lathe. pretty convenient if you ask me!

heres a pic jesse snapped while brazing the bottle mounts, i am looking a bit like a mad scientist in this one. i know i know, it is time for my spring hair cut and beard trim.

i needed more bottle braze-ons for my current frame project, so rather than order a bag of 10 for $3 and wait for them to get shipped to me, i opted to make 2 more just to hold me over. i need a couple other supplies so ill be putting in an order with henry james soon.

i started out with a length of mild steel rod, drilled out the center, then hand tapped it for an m5 bolt using the lathe as a guide.

once tapped i turned down the OD to a shoulder. the small diameter is 1/4".

then i parted it off, and made another. they look just like bottle mounts!
im gonna try not to run out of these any more!

Frame No. 2 - 9

IMG_4830, originally uploaded by rackntroll.

all cleaned up and ready for brake bosses.

Thursday, March 18, 2010

Frame No. 2 - 8

fork is built, measuring/checking mis-alignment. before building the fork i was debating whether to use my old fixture or build a new one.

i settled on not using one at all. *gasp*

i tacked it in a couple places then checked that the alignment was close to where it should be, then i went ahead and completed brazing in the legs.

came out pretty close, the biggest alignment issue was that the legs were spread pretty wide, around 110mm when i was done. i took some jumping on it to close it up to 100mm, actually a surprising amount of jumping.

Sunday, March 14, 2010

car trouble

i dunno if you've ever had a car crap out on you, but this was a first for me. it was quite an experience.

we were out late, and ran the tank pretty dry. on the way to get gasoline the car started sputtering and hesitating. im not talking little hesitations, more like bucking and lurching at low RPMs. at first if i kept it over 2000 RPMs it was okay, but it got progressively worse.

after we got gas on the way home it stalled out, and wouldnt restart. you shoulda seen me pushing the car across a parking lot in an attempt to push-start it (one of 3 reasons ill only ever own manual transmissions), then chasing after the car and hopping in on the move like in the movies. good times.

well the hesitations got worse, having to run it in higher and RPMs, and fighting it stalling out at speed and at stops. each time it stalled i downshifted to get the motor running again. luckily it was really late at night so i pretty much disregarded stop signs and 1 red traffic light to keep it rolling. it finally cut out altogether and would restart, 100 yards from our parking spot. i pushed it into place.

time to figure it out.... bc i ran the tank dry i figured i sucked up some nasty sediment from the bottom of the tank and clogged the fuel filter. so i changed that today, still wouldnt start.

heres the fuel filter and some nasty brown gas that came out. i thought for sure she would fire right up after this.

well after it didnt work i consulted my haynes repair manual, which is an absolute must for a DIY kinda guy. the trouble shooting section led my to check out the ignition coil. the primary coil should measure 10.5k - 16.5k ohms, and the secondary coil should measure .4 -.6 ohms.

time bust out the simpson 260, at one time the mainstay of the electronics industy.

this is the culprit, sure enough both coils measure out of spec.
tomorrow ill get a replacement, and see if that solves the problem.

so much for working on my fork today!!!

Friday, March 12, 2010

Frame No. 2 - 7

Pacenti MTB fork crown
All the casting ridges filed off
bending fork blades
dropout brazed in
flux soaked off dropout
steerer brazed into crown
the end is in sight

Wednesday, March 10, 2010

onto the next frame related project...

i have been debating using my original janky fork fixture just to get the frameset done....
but on the other hand im thinking i should make a new one. not entirely sure yet.

Monday, March 8, 2010

Frame No. 2 - 6

well, i got the seat stays in, so the frame is basically done except for the braze-ons and the fork.

before the seat stays went in, the chainstays were nicely aligned.

at some point during the installation of the seat stays something went wrong... horribly horribly wrong.

one dropout moved "up" causing the rear wheel to sit verrrryyy crooked. TIME FOR SOME MUSCLE.

well i bent the f*ck out the the rear triangle. some tubes buckled (sounds worse than it is), theres a few dents (from the vise jaws) and the stays are a little asymmetric, but in the end i won, the wheel sits straight and proper.

i certainly learned a lot from this mishap, im glad it went the way it did. if everything went in fine and dandy i would have never had this lesson in alignment.

Thursday, March 4, 2010

Frame No. 2 - 5

so after a pause in the construction to improve my fixture i made some new progress.
having a reliable easy to set up fixture made sizing, mitering, and checking fit of the chainstays a breeze. once the fixture is set to the proper height and length i can keep checking the fit of the stays as i cope them.

with a little help from the framebuilders list, alex w, a protractor, and BG101 (by martin manning, cant find a download link), i sorted out my chainstay length and miter angles.

everything cut to length and mocked up.

tacked the chainstays to the BB shell, then tacked and fully brazed the dropouts onto the other end, then returned the the BB shell and finished off the fillets. didnt come out as clean as the other fillets, the BB shell/chainstays is a pretty tough one to nail on your second try.


IMG_4713, originally uploaded by rackntroll.

simple yet effective, very easy to set-up.

Wednesday, March 3, 2010