Bicycle frame build.

[citizen kane]

As long as they are sharp it dosnt seem to mind. The white one is a cheap one from B&Q and seems to work just as well as the more expensive yellow Sarrett ones. I'm pretty sure they are both the same TPI.

Strawberry Cycles sell some really nice fine pitch holes saws http://www.strawberrybicycle.com/ga...ame=LAN71&id=Particle_Metal_mitre_cutters_001
At over $150 each compared to less than £5 for one I picked up on Sunday from screwfix

 

[NTwoO]

Very very nice project! I'll be following it with much interest. Past summer I built a recumbent out of Aluminium. At some point it'll be posted here as a project, but gotta do my tax first.

 

[aametalmaster]

Thats some fine tube fitting. Great job. ...Bob

 

[Gsus]

just amazing.
i think i'll need more sunflower seeds.

 

[chunkolini]

Beautiful mitring, I shall have to look at hole saws, but your geometry is all wrong, the angles are all over the place. Any fool knows this is what a proper bike looks like.




Note the passion and care that has gone into this beautiful machine, the quality of workmanship, the precision engineering. This is how to make a bike.

Chunko'.

 

[mike os]

precision engineering chunko...????? I cant see a jubilee clip anywhere

 

[hotrodder]

As long as they are sharp it dosnt seem to mind. The white one is a cheap one from B&Q and seems to work just as well as the more expensive yellow Sarrett ones. I'm pretty sure they are both the same TPI.

Strawberry Cycles sell some really nice fine pitch holes saws http://www.strawberrybicycle.com/ga...ame=LAN71&id=Particle_Metal_mitre_cutters_001
At over $150 each compared to less than £5 for one I picked up on Sunday from screwfix

Looking Good. No idea what the quality is like but FWIW Stakesys sell 10tpi holesaws, similar £ to slightly more expensive than Starrett 6tpi. Andrew Beattie & Co do a machined rather than welded holesaw that have tempted me a couple of times but i've yet to try 'em. Not a fine pitch design but supposedly cheaper to run than conventional holesaws (life versus initial cost), page 7 of this pdf

 

[citizen kane]

chunkolini, excelent bike, lets see a pic of you riding it.

I had a go at making a similar short wheel base bike, looking at the pics I think my drawing must have been wrong, should have spotted that before I started cutting metal.

hotrodder, thanks for the leads on holesaws, those German 10 tpi ones look like a good deal, may well order a few up and try them.

 

[chunkolini]

Quality work, uses old frames where possible, and a quality shock. You obviously love your luggage.

Chunko'.

 

[citizen kane]

A little more progress.

Seat tube sleeve machined up and ready to weld. Brass thing is an expanding heat sink.

Four 4mm diameter c/sunk holes plug welded.

Welds filed back and seat tube slot machined in. Slot stopped short of the top to aid final reaming of the ID

 

[breezer]

Wow - where did you get that expanding heat sink?

 

[citizen kane]

Wow - where did you get that expanding heat sink?

I make my own heatsinks, the only place I know you can buy them is hear http://www.paragonmachineworks.com/storename/paragonmachineworks/ViewDept-272213.aspx they also allow for backpurging, essential if your building in titanium.

 

[breezer]

eeeeek!

how do you make them?

 

[Gsus]

we are impatient for updates!!

 

[citizen kane]

Progress has slowed up with the delivery of a new carbon road bike and a good spell of weather.

This is wear I'm up to.

I've had a brass head badge engraved for the head tube.

Holes drilled in down tube for water bottle bosses.

I can't silver, I dont have oxyfuel so in the past I've fitted things like water bottle bosses and cable guides with soft solder. This method has proved fine for durability but normal soft solder means I cant have the frame powder coated as the oven gets to around 200C, to close to the solders melting point.

I've experimented with a high temp (300C) solder but its realy difficult to get it to tin the surfaces.

I took the down tube and water bottle bosses to a profesional welder to get them silver soldered into position, things didnt go well. Every thing was very very clean, loads of flux but all I ended up with was a black mess. Not realy sure what went wrong, this guy has years of experiance with silvering. There was an strange green tinge to the burnt flux that he hadnt seen before.

Anyway, I kind of want to be independant but I cant afford to by in oxyfuel so I've decided to tig braze these small fittings into place. I'm not going to use the bottle bosses in the picture, by the time they are tig brazed into position all the detail will be lost so I will turn up some simple inserts instead.

So, next I need to get some practice tig brazing and see how I get on.

 

[chunkolini]

Interesting stuff, and beautifully made, can I have a go on it when it is finished?
A carbon road bike?
Burned toast and glue, how can you make a bike out of that?

Chunko'

 

[oz.]

Ford made car out of rust and spit with a bit of pain on top so burnt toast and glue sounds a step up from Ford

 

[wavestarved]

Wow, blown away. My dad would love this thread; right up his alley.

 

[citizen kane]

Interesting stuff, and beautifully made, can I have a go on it when it is finished?
A carbon road bike?
Burned toast and glue, how can you make a bike out of that?

Chunko'

Of course you can have a go, normal china shop rules of course.

I've spent at least 20 years working with aerospace carbon fibre, mostly on the non destructive inspection side. Every now and then I would get an approach from a "sports" composite manufacture to have a look at their product and to be honest the quality has in general been shocking. Sure it looks nice but the levels of porosity are generally so bad that the material turns into a black hole for ultrasound. I guess at the end of the day its strong and stiff enough for the job, most carbon frames are only marginally lighter than a well designed alloy frame.

Still brought one though. Have a look hear if you want to see some cool carbon failures http://www.bustedcarbon.com/

Anyway, back to the frame. I spent some time at the weekend playing with tig brazing. Its pretty easy to join stuff but next to impossible to get the filler to flow so I gave up on that.

So I had a go a silver soldering with a propane torch and seem to have produced a resonable workman like result, prehaps a little to much silver and a bit to much heat but good enough to hold a water bottle cage.

I'm running out of excuses now, going to have to weld soon.

 

[Shox Dr]

I've spent at least 20 years working with aerospace carbon fibre, mostly on the non destructive inspection side. Every now and then I would get an approach from a "sports" composite manufacture to have a look at their product and to be honest the quality has in general been shocking. .

GT made a Carbon Fibre frame called the Lobo. It was sooooooo bad the head area was solid, and you could still tear the headstock of it, hitting such as a kerb