tag:blogger.com,1999:blog-86381549535944349392024-02-07T14:59:47.224-08:00Curmudgeon BicyclesRead as a grumpy amateur builds his first... er, now third bike! Note to readers: I've never done any of this before, do not copy me without further research and sense (common or otherwise).Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.comBlogger37125tag:blogger.com,1999:blog-8638154953594434939.post-72687785824995330592015-01-19T00:19:00.001-08:002015-01-19T00:27:06.540-08:00Brazing cleanup photo montage<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDksoRHqTS1vUIF8vuPdd4S-tvjX0sWBWi_GCReFZJdUzmwlPxhv6UEkvJJq19ww1qj95l5obmB7Nb0puuGTdxd1wvr0vc6rnGfKjUNspuHEGkgvGrVqJAvQsUwONIvrrOZ5O9Olk87nH9/s1600/IMG_20150118_231305830.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDksoRHqTS1vUIF8vuPdd4S-tvjX0sWBWi_GCReFZJdUzmwlPxhv6UEkvJJq19ww1qj95l5obmB7Nb0puuGTdxd1wvr0vc6rnGfKjUNspuHEGkgvGrVqJAvQsUwONIvrrOZ5O9Olk87nH9/s1600/IMG_20150118_231305830.jpg" height="320" width="180" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG0cP42YcJpftTdeldG3NmSPt8FSBCmaT3bl9rITWrWD_hQlzLEvv5_jdbTmWCL9I5CEenPxfDcle8m-AjASb5AUT7zXauhWHZ29E3WGPqFlC4fJGteWo1hpNTP3KQ5eJsO8ilfBQRjy-d/s1600/IMG_20150118_230553949.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG0cP42YcJpftTdeldG3NmSPt8FSBCmaT3bl9rITWrWD_hQlzLEvv5_jdbTmWCL9I5CEenPxfDcle8m-AjASb5AUT7zXauhWHZ29E3WGPqFlC4fJGteWo1hpNTP3KQ5eJsO8ilfBQRjy-d/s1600/IMG_20150118_230553949.jpg" height="320" width="180" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZuLRgdNa-xfsCroL65mRwhToGcFgENXhaj2DC59O9gN5YiFoxDijDAvwXDLaBCA0Oj4ggi0kmvlvPko8Uiz6kAtM1uUb2YYYzwbDbrv3BPNWuV__AdInra1u7sqOleWHS2toWanksRF9u/s1600/IMG_20150118_230603787.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZuLRgdNa-xfsCroL65mRwhToGcFgENXhaj2DC59O9gN5YiFoxDijDAvwXDLaBCA0Oj4ggi0kmvlvPko8Uiz6kAtM1uUb2YYYzwbDbrv3BPNWuV__AdInra1u7sqOleWHS2toWanksRF9u/s1600/IMG_20150118_230603787.jpg" height="320" width="180" /></a></div>
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Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-62200857068150987692015-01-08T18:48:00.003-08:002015-01-08T18:49:03.771-08:00Mini-update<div class="separator" style="clear: both; text-align: left;">
I brazed the brake and chainstay bridges on Monday. I wanted to keep the height consistent between the front and back brake. I also wanted the fender mounts to be the same distance from the dropout. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhO47XEXWHqJojBAJpOA61dY2q5QlKseOHBbElYnopZLFa-dk3NasjtyZmCnecnRt_IVau7NF0McWvn8ZwT5AbbVUIftpswPwnb8w5IUcUrTRUv_1G_GJ5RNL0lWSE9Ha-rBDWtp3DoMini/s1600/IMG_20150105_180830750_HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhO47XEXWHqJojBAJpOA61dY2q5QlKseOHBbElYnopZLFa-dk3NasjtyZmCnecnRt_IVau7NF0McWvn8ZwT5AbbVUIftpswPwnb8w5IUcUrTRUv_1G_GJ5RNL0lWSE9Ha-rBDWtp3DoMini/s1600/IMG_20150105_180830750_HDR.jpg" height="320" width="180" /></a></div>
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I measured things out with a pair of Anvil axles and a bent brazing rod. Once I had the approximate position of the bridge, I found the widths of the deepest cuts with a caliper, added some breathing room, marked them, and went to work with a file. It took some trial and error, but I got things nice and even for the brake bridge. Doing the last tiny bit with some emery cloth and a scrap seat stay really helped.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitggvd21bC2z6nlMP7Wp27lTIr_qPYt0oyu1DfPUwGckku-5bzL7ZWXzjbreLhWf4Jf0TOyL1IjGMvwvZuqLQL32nKMHwUqP2_ZWKsxR0nwN1wEjByG5pqpPvQyat0J3cj53dgTcJH-MLX/s1600/IMG_20150105_180042354.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitggvd21bC2z6nlMP7Wp27lTIr_qPYt0oyu1DfPUwGckku-5bzL7ZWXzjbreLhWf4Jf0TOyL1IjGMvwvZuqLQL32nKMHwUqP2_ZWKsxR0nwN1wEjByG5pqpPvQyat0J3cj53dgTcJH-MLX/s1600/IMG_20150105_180042354.jpg" height="179" width="320" /></a></div>
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The brazing went pretty smoothly. I think I'm starting to get the hang of 50N silver. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgobXKqRDfWK_U3Mvs_jVIEPG359BP5IS3nVQQH3IinvtdPOqL82gsFYxkmXs2a3HVje_Ua1PTZk1W1Ga1Fk2ZHY3Fh0ZtdNpdVgavUoJFJ1v0BKo_yMQubFWOn8pGd8RRF0BRC5yD56A7D/s1600/IMG_20150105_185955266.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgobXKqRDfWK_U3Mvs_jVIEPG359BP5IS3nVQQH3IinvtdPOqL82gsFYxkmXs2a3HVje_Ua1PTZk1W1Ga1Fk2ZHY3Fh0ZtdNpdVgavUoJFJ1v0BKo_yMQubFWOn8pGd8RRF0BRC5yD56A7D/s1600/IMG_20150105_185955266.jpg" height="179" width="320" /></a></div>
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Here's one of the fender eyelets in inaction. I just drilled a hole in each bridge, cut the eyelet short enough not to get in the way of brake mounting, etc, and brazed it in place.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRWhrvtQYm0DYgyrJhbkM_nHILMb6q0-DfzasIIYgsskwxV2lWot5oC6SlWql6OYITcwTQvO9ddCm91s5xmL-hu5cYz9uUidHm5pxVV6NCbF0CkDXbTqJLeAs0scyNwws0NEIp6oblGXPe/s1600/IMG_20150108_184143536.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRWhrvtQYm0DYgyrJhbkM_nHILMb6q0-DfzasIIYgsskwxV2lWot5oC6SlWql6OYITcwTQvO9ddCm91s5xmL-hu5cYz9uUidHm5pxVV6NCbF0CkDXbTqJLeAs0scyNwws0NEIp6oblGXPe/s1600/IMG_20150108_184143536.jpg" height="640" width="360" /></a></div>
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Next week: sealing the seat stays, touch up with solder, grinding out the tubes in the BB area, thinking about cargo racks.</div>
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<br />Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-37038502398227753142014-12-30T23:06:00.000-08:002014-12-30T23:11:47.699-08:00Rear Triangle!<div class="" style="clear: both; text-align: left;">
Over the last week I've gotten the rest of the rear triangle done. Step one was getting the other chainstay installed and adjusted to keep the rear wheel straight. I was pretty close and it only took a bit of bending to get it to 90 degrees. As before, I referenced the head tube to try to keep everything in line.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh7N5F4GqT5B5u3met1slm88ioJg6L-ed3dwgfAtpqD3MvawQiN0gHBSIoXrYJWAa5ZT7CwP0kJSxpttnmViMXo-cT1A8lNbrmIzI0lyt2Ho0zO_wiq-NhyphenhyphenH2mkiEqKDEvyYXfy6SEHUuD/s1600/IMG_20141227_193215353.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh7N5F4GqT5B5u3met1slm88ioJg6L-ed3dwgfAtpqD3MvawQiN0gHBSIoXrYJWAa5ZT7CwP0kJSxpttnmViMXo-cT1A8lNbrmIzI0lyt2Ho0zO_wiq-NhyphenhyphenH2mkiEqKDEvyYXfy6SEHUuD/s1600/IMG_20141227_193215353.jpg" height="180" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrsEAYv4dBVsaeWi0_tjcIEkEovQlgr4Y9_rkdUgeBcrrocDoDLtSaL4pn2mfOPYWgAJVTcH_Wt5e1t47vGr6s9EPp9qbnkvQ8y9S3Q1c1dHXwlcNy1ssJ0e8LcedMi5gSQ_mQRZXaQYjD/s1600/IMG_20141227_193033671.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrsEAYv4dBVsaeWi0_tjcIEkEovQlgr4Y9_rkdUgeBcrrocDoDLtSaL4pn2mfOPYWgAJVTcH_Wt5e1t47vGr6s9EPp9qbnkvQ8y9S3Q1c1dHXwlcNy1ssJ0e8LcedMi5gSQ_mQRZXaQYjD/s1600/IMG_20141227_193033671.jpg" height="180" width="320" /></a></div>
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Then it was on to the seatstays. I really like a particular kind of scalloped end cap. It's made by brass brazing a piece of 31.8 tubing to the end, then cutting it out and filing it down. I use brass because it won't melt when silver brazing the finished piece on the side of the seat lug.</div>
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMmLeHUWGTgnvaGy1t0L_m0vWg-KFTKMIyxHUp5YCr0xoa7HbqcltgUcrgmgtSh3CDgmYRC0hgx9c_oBIp4C8e8JTmJ8EQ4J6p6MompENAVqyGk6izPrMU-M1P3k95GPzoEe7R5WfoIfmg/s1600/IMG_20141224_180413929_HDR.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMmLeHUWGTgnvaGy1t0L_m0vWg-KFTKMIyxHUp5YCr0xoa7HbqcltgUcrgmgtSh3CDgmYRC0hgx9c_oBIp4C8e8JTmJ8EQ4J6p6MompENAVqyGk6izPrMU-M1P3k95GPzoEe7R5WfoIfmg/s1600/IMG_20141224_180413929_HDR.jpg" height="320" width="180" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px;">Miter template and rough cut.</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLb18bj4po96vV4tpfqJ53G66PaC2VWIoF9AQgXcIL9wx6NYR6o2Nvo6HaKEgwPRxsAFXQPAQnXaHqxyzIIdrGN4UaBb21wa6dGzQGvMCRU9LAd61AiiVwmyL2Dt9HwAYz22joQ57QUwtx/s1600/IMG_20141224_195559758.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLb18bj4po96vV4tpfqJ53G66PaC2VWIoF9AQgXcIL9wx6NYR6o2Nvo6HaKEgwPRxsAFXQPAQnXaHqxyzIIdrGN4UaBb21wa6dGzQGvMCRU9LAd61AiiVwmyL2Dt9HwAYz22joQ57QUwtx/s1600/IMG_20141224_195559758.jpg" height="320" width="180" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Finished miter and notch. <br />
The notch increases the<br />
surface area of the braze.</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkXrrg3Ff9KhsF8xiq1QmaZJjPMfDPibXJxiV1sG-SCNK-FzezPgLSFc84mhyphenhyphenz8KaIEF7s8QMjZan4-21xBkePfuWBotMYvh_VjidhNyCqfK7Ll0FwumixMLQJdpmGiyWj8SP3nPTeV1AB/s1600/IMG_20141226_072720432.jpg" imageanchor="1" style="clear: right; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkXrrg3Ff9KhsF8xiq1QmaZJjPMfDPibXJxiV1sG-SCNK-FzezPgLSFc84mhyphenhyphenz8KaIEF7s8QMjZan4-21xBkePfuWBotMYvh_VjidhNyCqfK7Ll0FwumixMLQJdpmGiyWj8SP3nPTeV1AB/s1600/IMG_20141226_072720432.jpg" height="223" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Trimming the excess, post brazing.</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTI88u5G4WcdWKRacrI7plLIRsZ5GA4zUJgVLJ7ifJPKSJ-nzeh-JKAcXUF66XjJ6Ou92JOn0YfDeg9cRKJtoGwQf-laCDUG3zYfvyVh4uIgQzLBE_ZAxFyTPPmjt6B95l_EILv6MRdmaf/s1600/IMG_20141228_223426022_HDR.jpg" imageanchor="1" style="clear: right; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTI88u5G4WcdWKRacrI7plLIRsZ5GA4zUJgVLJ7ifJPKSJ-nzeh-JKAcXUF66XjJ6Ou92JOn0YfDeg9cRKJtoGwQf-laCDUG3zYfvyVh4uIgQzLBE_ZAxFyTPPmjt6B95l_EILv6MRdmaf/s1600/IMG_20141228_223426022_HDR.jpg" height="225" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Stays: completed.</td></tr>
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Attaching the stays was pretty straightforward. A little pressure at the top and a pin in each dropout kept things in place while I got the first two brazes done, then I moved the clamp down to braze the tops. Both were done with 50N silver because the bottom was a bit gappy and the top needed to build up a bit of a fillet for strength. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8MZhjFMXqN5B8tpYBcrUpxnDKL9oaFLQfAjV_OTNSWvaOtsS-nB_YD0Dsdv8cfSXv1oZbRpKQFf1RSCuUsdU4csbQ9coPjhEU3H3lHbJQTQ8Z0BYLs19X5kj_VnW9kxpTihhj6HzM5n4Y/s1600/IMG_20141230_195312983.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8MZhjFMXqN5B8tpYBcrUpxnDKL9oaFLQfAjV_OTNSWvaOtsS-nB_YD0Dsdv8cfSXv1oZbRpKQFf1RSCuUsdU4csbQ9coPjhEU3H3lHbJQTQ8Z0BYLs19X5kj_VnW9kxpTihhj6HzM5n4Y/s1600/IMG_20141230_195312983.jpg" height="180" width="320" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnFAIx_PQ84Ps8l-ylSpaSwFo_3bliAVUXeuI-cif79T23EOnU8qXXBpQK6sOtW9PAbvlZbuMR7PZoXtppCeVjbTjBYsXk1pprdU2bdBHS7doAx-viXcCCCQOnMMEBN9iwRpA6y0Z8t4NS/s1600/IMG_20141230_195322409.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnFAIx_PQ84Ps8l-ylSpaSwFo_3bliAVUXeuI-cif79T23EOnU8qXXBpQK6sOtW9PAbvlZbuMR7PZoXtppCeVjbTjBYsXk1pprdU2bdBHS7doAx-viXcCCCQOnMMEBN9iwRpA6y0Z8t4NS/s1600/IMG_20141230_195322409.jpg" height="320" width="180" /></a></div>
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<tr><td class="tr-caption" style="text-align: center;">Brazed!</td></tr>
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<br />Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-7414185230330749792014-12-23T22:43:00.000-08:002014-12-23T22:50:45.244-08:00Right Stay<div class="separator" style="clear: both; text-align: left;">
I started on the rear triangle on Sunday!. My strategy is to get the right side just where I want it, then I can put a wheel/<a href="http://www.cycle-frames.com/bicycle-frame-tubing/T-SQUARE-130mm-FOR-REAR-END.html" target="_blank">rear triangle t-square</a> in it to properly align the left chainstay. I'm mostly going at it this way because my homemade jig doesn't keep the dropouts lined up perfectly, and the extra steps let me tweak it on the fly.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihvufMB5csNNIPViOC3l_pSiHl7dw67ahjHT48EdkyIQuxDmy5VfiYBrUuLnxXB5lyGBiizLZu63rgYcitAorUSvsqqVUP22p_4Gg4C_kpu8SZeXfkqV77UIb91MdTttGLfiAnyPC1Aczy/s1600/IMG_20141223_215622361.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihvufMB5csNNIPViOC3l_pSiHl7dw67ahjHT48EdkyIQuxDmy5VfiYBrUuLnxXB5lyGBiizLZu63rgYcitAorUSvsqqVUP22p_4Gg4C_kpu8SZeXfkqV77UIb91MdTttGLfiAnyPC1Aczy/s1600/IMG_20141223_215622361.jpg" height="180" width="320" /></a></div>
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The dropout went on easily. I used some more of the 50N silver; I think I'm starting to get a better feel for it. It certainly seemed to jump when I wanted it to.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsL_O8eD5LhXc-nWi6YsSBwzaO7Ex6Iee68Wke9NRzOKo4OnxLAC4IZXN0q2fUCNFqVmBVXOlZ_j8gTAue9voBXQ8aibIgWldd5Yuix1wKyYt82PiXwBOdCgBWUw-ahm_0pDGccw3exQZM/s1600/IMG_20141221_184840113.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsL_O8eD5LhXc-nWi6YsSBwzaO7Ex6Iee68Wke9NRzOKo4OnxLAC4IZXN0q2fUCNFqVmBVXOlZ_j8gTAue9voBXQ8aibIgWldd5Yuix1wKyYt82PiXwBOdCgBWUw-ahm_0pDGccw3exQZM/s1600/IMG_20141221_184840113.jpg" height="180" width="320" /></a></div>
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I pinned the bottom bracket in the jig using the <a href="http://cycledesignusa.com/wp/?page_id=197" target="_blank">square profile nails that Cycle Design sells</a>, then brazed it freehand.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUU3F0t8pnDxmPJA8AmKwjRGNZDpqoOKev9qVZbpGk2TB0Pjc-BEpJ0V9pXEOimA3hrr6-aYCiBVP9AbR9D8fFQrlBYDkfWQCK2WXZ8lKuY6Z-yS0xUj317-FPyAtxnkIabudDP_gD1ijU/s1600/IMG_20141221_184844097.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUU3F0t8pnDxmPJA8AmKwjRGNZDpqoOKev9qVZbpGk2TB0Pjc-BEpJ0V9pXEOimA3hrr6-aYCiBVP9AbR9D8fFQrlBYDkfWQCK2WXZ8lKuY6Z-yS0xUj317-FPyAtxnkIabudDP_gD1ijU/s1600/IMG_20141221_184844097.jpg" height="225" width="400" /></a></div>
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The one issue I noticed was that the pins wanted to draw the stay up just a little bit from how it fit in the Jig, so I used the sophisticated method pictured above the add a little weight to the end.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjxs2lsZ68y2z6197F6J2Z9pvtJLJ3ukcq-LxDFODFHH7uHPaXoa1mypxyF-rcqpfjleYcJIlk5AKvnNNA5if50-2K3rBJkLwaTO0j0SW0NDOeuPFvwT3Kb5AQV3ETDS-OZGFuR58bmgwv/s1600/IMG_20141223_215521450.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjxs2lsZ68y2z6197F6J2Z9pvtJLJ3ukcq-LxDFODFHH7uHPaXoa1mypxyF-rcqpfjleYcJIlk5AKvnNNA5if50-2K3rBJkLwaTO0j0SW0NDOeuPFvwT3Kb5AQV3ETDS-OZGFuR58bmgwv/s1600/IMG_20141223_215521450.jpg" height="400" width="225" /></a></div>
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Here it is, brazed and soaked. On this bike, I've left all of the bottom bracket miters a bit long., with the intention of grinding the inside smooth when I finish. </div>
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As a bonus, here's a picture of my cable routing:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNMpLWfjUX0qfEsgIpW9p8WB1MCYO0JdcpRZNsIYRlKYQCmxlji2h5kSFlZWZT-V301dAo5Gz0ZGPWfp8upGMxz6NZ-maDhEiG1hb6HY-yE2ksGf5mtxVQyVXzrTjPGhN89pWA_wupsFzE/s1600/IMG_20141223_221705233.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNMpLWfjUX0qfEsgIpW9p8WB1MCYO0JdcpRZNsIYRlKYQCmxlji2h5kSFlZWZT-V301dAo5Gz0ZGPWfp8upGMxz6NZ-maDhEiG1hb6HY-yE2ksGf5mtxVQyVXzrTjPGhN89pWA_wupsFzE/s1600/IMG_20141223_221705233.jpg" height="180" width="320" /></a></div>
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Crossing the cable from the right shifter to the left side of the down-tube (and the left to the right) keeps the housing from having sharp bends, but looks a little odd since the cables must cross back under the down tube. I spent a little time with some stainless tubing to solve that. It's silly, it's overkill, but I like it. This way the correct cable goes to the correct shifter, but the cross happens out of sight so the cables will stay roughly parallel to the down tube. As it turns out, this stainless steel ball of spaghetti creates very little friction.</div>
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For the curious, here's the great <a href="http://sheldonbrown.com/cables.html#crisscross" target="_blank">Sheldon Brown's take</a> on crossing the cables. To keep things balanced, here is an <a href="https://www.youtube.com/watch?v=jyaLZHiJJnE" target="_blank">opposing viewpoint.</a></div>
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Also worth noting, I've drilled the bottom bracket for drainage. Almost all water related damage that I've seen or heard of on a bike was the result of standing water, not just exposure. Hell, I've been riding my first build, sans-paint, in the rain on and off, for years and the rust hasn't made any real progress. Since I can't totally seal this area (there's always the potential for a little water to sneak in through the seat tube), I wanted there to be a good way for it to drain.</div>
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<br />Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-73421481087254049242014-12-16T20:37:00.001-08:002014-12-16T20:37:57.202-08:00Jig Interlude<div class="separator" style="clear: both; text-align: left;">
This is a quick one, but there'll be more this weekend.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4nhaXYa854m0iE7biFjtxjsYAvB6PBdEjFLVe6M4mwe1pSI-4Nca9I-C2o2Cg04aVH0dY2X90UghVbS9CNoe3YHobkh1T1WEh3eszGdNzFoic45nEvEZVBdhdghdVVVU1ZmGG-zuNP2xP/s1600/IMG_20141214_154546544.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4nhaXYa854m0iE7biFjtxjsYAvB6PBdEjFLVe6M4mwe1pSI-4Nca9I-C2o2Cg04aVH0dY2X90UghVbS9CNoe3YHobkh1T1WEh3eszGdNzFoic45nEvEZVBdhdghdVVVU1ZmGG-zuNP2xP/s1600/IMG_20141214_154546544.jpg" height="360" width="640" /></a></div>
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Here's my home made jig. I've got the front triangle (already brazed) clamped in it. I'm using my incredibly intricate chain-stay angle/length tool to set it up for brazing on the chainstays. I use a digital angle gauge while I jostle it around to find the point where the angles match up with my rattlecad diagram. </div>
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Two quick points: </div>
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1) This works way better with a rigid piece of metal.</div>
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2) Referencing off of the head tube instead of the seat tube should yield better results (with a little math). If the seat tube is forward or back a half degree, you'll most likely be able to account for it with the fore-aft position of your saddle. If the relative angle of your head tube and chainstays is off, your bottom bracket height will change as will some of the steering characteristics.</div>
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Cheers, have a good week.</div>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAOR8rnNd4AapVUw4Plw9HgCv6lmuqKTpZgt4AHNACFeOAxpcc4MH_NaEZ8HKYGH4BjRfbLAetmizOjoQ9rVtqnT3ZYWLX6_YHbYy1EGnAHCj8bBzeiT9K548Ds7XbqiCetw4GAzducrVH/s1600/IMG_20141214_162431083.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAOR8rnNd4AapVUw4Plw9HgCv6lmuqKTpZgt4AHNACFeOAxpcc4MH_NaEZ8HKYGH4BjRfbLAetmizOjoQ9rVtqnT3ZYWLX6_YHbYy1EGnAHCj8bBzeiT9K548Ds7XbqiCetw4GAzducrVH/s1600/IMG_20141214_162431083.jpg" height="360" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">HIGH TECH!</td></tr>
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<br />Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-33797660402623324312014-12-11T00:51:00.000-08:002014-12-11T00:54:16.935-08:00Fork, Part 2<div class="separator" style="clear: both; text-align: left;">
Had some time to work on the fork this week. The fit up on the crown was a bit on the gappy side, so I went with 50N silver instead of my customary 56%. </div>
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56% flows faster, melts at a slightly lower temperature, and I just generally love working with it. </div>
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50N is a bit thicker, and a bit more sluggish. It has a few advantages: it will fill larger gaps, it will form small fillets for strong joints on brake bridges/other high stress braze-ons, and I'm told that it wets out more easily on stainless steel than some other silver alloys.</div>
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The downside is that I just haven't gotten the hours in with it to feel totally confident when it's necessary. I ended up doing a second pass to make sure I had good penetration, and definitely crisped some flux near the end (should have let it cool down and re-fluxed it instead of heating it right back up).</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEislDhTdGDc8hGiAabYL7CUXH5FO8P5VSBbv_tirgf5RMF_g_XPtpRl6toJS-drIUWe94_z7ZnU5pkXDbPeQufM2UYvjuvYb7HO0oNyAq1y3_hJSZ16uYevWfKd0ahkKHLTUnZHRgqKrnxt/s1600/IMG_20141129_154406289.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEislDhTdGDc8hGiAabYL7CUXH5FO8P5VSBbv_tirgf5RMF_g_XPtpRl6toJS-drIUWe94_z7ZnU5pkXDbPeQufM2UYvjuvYb7HO0oNyAq1y3_hJSZ16uYevWfKd0ahkKHLTUnZHRgqKrnxt/s1600/IMG_20141129_154406289.jpg" height="320" width="180" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuB0pY-LgVXvNH0PbMRJBaTPjJHmAbV3brcERZiK3vKr2IsmmPWHrpSWdnZ2BKCedGgUVCkiESxy6scoMb5i5F1suwJUcO50Lta2Sd1EdHurRqZ4SpFLAUbYd-j31LxBT-OfAxPQHd5B6V/s1600/IMG_20141129_161408703.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuB0pY-LgVXvNH0PbMRJBaTPjJHmAbV3brcERZiK3vKr2IsmmPWHrpSWdnZ2BKCedGgUVCkiESxy6scoMb5i5F1suwJUcO50Lta2Sd1EdHurRqZ4SpFLAUbYd-j31LxBT-OfAxPQHd5B6V/s1600/IMG_20141129_161408703.jpg" height="320" width="180" /></a></div>
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That said, I think I'm going to stick with this one. I was able to draw the silver through to the pins, and I think it's unlikely that I have a bad fill.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1K210e-ND1svKqxk06wZcZVeG1xapeivAWDLwcI5pTPgI3FYd0w5_w6xtLA0Kp1V1YyHdBJAvJx9zf6MfqTB2pqH8bD8dhQ14G7lx4S2-ebeuyFF6HLKELwm8JGFvkmpCxtP-r8_uroys/s1600/IMG_20141210_224149842.jpg" imageanchor="1"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1K210e-ND1svKqxk06wZcZVeG1xapeivAWDLwcI5pTPgI3FYd0w5_w6xtLA0Kp1V1YyHdBJAvJx9zf6MfqTB2pqH8bD8dhQ14G7lx4S2-ebeuyFF6HLKELwm8JGFvkmpCxtP-r8_uroys/s1600/IMG_20141210_224149842.jpg" height="225" width="400" /></a></div>
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Here's the crown all cleaned up. I love <a href="http://www.henryjames.com/bicyle-parts/bike-fork-crowns.html" target="_blank">Henry James' crowns</a>, they have this beautiful elegance to them. I can't wait to see it with some paint on it.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8nhifHDW7WM7Hfm9ERPmLSqFei_Al3PT0dOwgdlcnQjQ_EfLAz2IP3hMgB-_196c2D2I2s66vsk9AccN0g4jiO7L3qSTjCnhkB_ls-f-X_1RffByN4gH4YOh7Kqt_ZBDlg6wf-1fOeGcX/s1600/IMG_20141210_224141491.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8nhifHDW7WM7Hfm9ERPmLSqFei_Al3PT0dOwgdlcnQjQ_EfLAz2IP3hMgB-_196c2D2I2s66vsk9AccN0g4jiO7L3qSTjCnhkB_ls-f-X_1RffByN4gH4YOh7Kqt_ZBDlg6wf-1fOeGcX/s1600/IMG_20141210_224141491.jpg" height="225" width="400" /></a></div>
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I also love hourglass spindles. I set these up to work with <a href="http://www.rivbike.com/product-p/rmf2b.htm" target="_blank">Nitto/Rivendell's Hub Area Rack</a>. It's a gorgeous piece of gear. I can't imagine actually needing four bags for the kind of riding that I do... but WHAT IF? </div>
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Worth mentioning: I used 50N for these rack mounts too. Note the nice little fillet around the base of each of them. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDFsnCdugTbU6qkUfiMZvqh-CERNYD_G3oaiAD5h1smSCWgg_eKxhRPjbKvHkFBlMcvBw1OFFLUhFAzcyUWXtT4wclELQw9nx32WAqhiCHoJCxZSHDE79PPKSiaHZmR92ZzYWkdVPWCxA1/s1600/IMG_20141210_224127276.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDFsnCdugTbU6qkUfiMZvqh-CERNYD_G3oaiAD5h1smSCWgg_eKxhRPjbKvHkFBlMcvBw1OFFLUhFAzcyUWXtT4wclELQw9nx32WAqhiCHoJCxZSHDE79PPKSiaHZmR92ZzYWkdVPWCxA1/s1600/IMG_20141210_224127276.jpg" height="360" width="640" /></a></div>
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Here's the whole thing. It needed a bit of a twist, but I've gotten it pretty straight. </div>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxHorJDYOfMNoZbty2w9NMwWGGcDYconFGVxIpdezVQ2D4KvVyH2aDiVxasPPME_5qk6xUN63ThcAhOnLX7UEPsUtXzVDdgJXx70D5wA7cz72TLl7ZIauIOALKglZG5ptym5LP165K1j4m/s1600/IMG_20141210_224949393.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxHorJDYOfMNoZbty2w9NMwWGGcDYconFGVxIpdezVQ2D4KvVyH2aDiVxasPPME_5qk6xUN63ThcAhOnLX7UEPsUtXzVDdgJXx70D5wA7cz72TLl7ZIauIOALKglZG5ptym5LP165K1j4m/s1600/IMG_20141210_224949393.jpg" height="180" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;"><span style="font-size: small; text-align: left;">Bonus image: my co-blogger, Gimble. She gets her own chair.</span></td></tr>
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<br />Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-39469749375863043392014-11-29T11:17:00.000-08:002014-11-29T11:17:33.247-08:00Badge Redeux, Part 1<div class="separator" style="clear: both; text-align: left;">
Taking another pass at badges. I really lucked out on having generous and artistic friends! This is the badge for bike #3, which I'm calling the Racing Pug. My friend L did the sketch based on some pug/goggle pictures that I scrounged and I did the text.</div>
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There are two main differences between this badge and the previous ones. First, I'm using some purpose made transfer paper called Stick and Peel Blue. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiprS-CaoGUsuC70ylcxNfrt8wPMQuSyfb1b7LTGg0SlmHt7BpQ_AK7OwkLTJvmV9ARxTGKpAXJg3E5iUmVMxr507KXrLi7FLVrj3uMmJO_q1GwxQ-vtjx00JoDBbyc99d0ETNY7IPq_qCL/s1600/IMG_20141126_074450749.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiprS-CaoGUsuC70ylcxNfrt8wPMQuSyfb1b7LTGg0SlmHt7BpQ_AK7OwkLTJvmV9ARxTGKpAXJg3E5iUmVMxr507KXrLi7FLVrj3uMmJO_q1GwxQ-vtjx00JoDBbyc99d0ETNY7IPq_qCL/s1600/IMG_20141126_074450749.jpg" height="180" width="320" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPkNdM3SNqxcb-qAbkSljZzcBBmF4R2IW-4gfxOh-SlTWHvkEN1SO_SfimF1rVI3WGp_La8IwZdEh5AswA-VivNAcV2yzXSTiPrhSdaydgMq3VwvRCIudYi18ICNX1byIVl5OlN6n3L7Yi/s1600/IMG_20141127_131129502_HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPkNdM3SNqxcb-qAbkSljZzcBBmF4R2IW-4gfxOh-SlTWHvkEN1SO_SfimF1rVI3WGp_La8IwZdEh5AswA-VivNAcV2yzXSTiPrhSdaydgMq3VwvRCIudYi18ICNX1byIVl5OlN6n3L7Yi/s1600/IMG_20141127_131129502_HDR.jpg" height="200" width="112" /></a></div>
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It works about the same way that the magazine solution does. You print on it with a laser printer, iron it over onto a piece of metal, then dip acid. I found that this worked best without pre-heating and at a higher setting on the iron (might just be the brand of toner). </div>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWDy62byFpQN7c_9wynTHyZUVfjMa-P0VuC1PpbHUarRiobqqDZoYmhoqhf5om6yYMiBq2thfzfbBQ1unvKu84IsVr12rOsTf09PyNGuASKpZ58dHfgMUoYTOrfg3Or1n_JRM4yK4kYlXj/s1600/IMG_20141128_132720943_HDR.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWDy62byFpQN7c_9wynTHyZUVfjMa-P0VuC1PpbHUarRiobqqDZoYmhoqhf5om6yYMiBq2thfzfbBQ1unvKu84IsVr12rOsTf09PyNGuASKpZ58dHfgMUoYTOrfg3Or1n_JRM4yK4kYlXj/s1600/IMG_20141128_132720943_HDR.jpg" height="320" width="180" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Supervision.</td></tr>
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The other big difference was that I was etching stainless steel instead of copper or brass. Stainless etches more slowly and leaves a lot of sediment (dusty grit, the leftover steel from the reaction), but it does work. I tried brushing the sediment out of the lines with a sponge, but that seemed to lift the edge of the resist a bit, and lead to blurry lines... so I might have to live with a somewhat shallow etch.<div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5B_p05tJ_fxwpOBwbJGMF5m88aFgg2KIZ87atAspp1EHhOEL6l6hpYy2_0g-_eOS3sXgVolfpR3pu6KKOwH048drX6ACDRjGKix67wQQRkD2VLuQFfFj8LT2l9cnbsnX7E4-7zkj5bgKj/s1600/IMG_20141129_103153654_HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5B_p05tJ_fxwpOBwbJGMF5m88aFgg2KIZ87atAspp1EHhOEL6l6hpYy2_0g-_eOS3sXgVolfpR3pu6KKOwH048drX6ACDRjGKix67wQQRkD2VLuQFfFj8LT2l9cnbsnX7E4-7zkj5bgKj/s1600/IMG_20141129_103153654_HDR.jpg" height="640" width="360" /></a></div>
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That said, it turned out pretty well. I'm going to have to figure out a good way to darken the lower area, or to darken the whole thing so that I can polish the surface back to brightness. I'll finish it by cutting out the negative space above and below the badge so that it'll have some interesting outlines, then using a tube-block to bend it into the right shape.</div>
Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com1tag:blogger.com,1999:blog-8638154953594434939.post-46363414641842990902014-11-22T23:02:00.001-08:002014-12-11T00:54:35.713-08:00Fork, Part 1<div class="separator" style="clear: both; text-align: center;">
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It's been a <a href="https://www.youtube.com/watch?v=tax4e4hBBZc" target="_blank">loooooong </a>time.</div>
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Over the last couple of years, I finished the bike I was working on, made a sweet single speed, and rode them both a bunch. I made a lot of progress with my brazing, but still count as a dangerous amateur. </div>
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I've done a few practice forks, and I think this one will turn out well enough to bomb down big hills on.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzGKEKbjPm06tAhnuCVc1v488kg3sFTWWzcrg-rt5pTKENdqXLPHCtrOtL7HjXR55yNf8QAsLwdwXTkCO1DikVEHowiIrEwQoSbT5VW27NOHUtIumMFI9feuP6kAddpE4cUXcmLZt1CrXP/s1600/IMG_20141121_214717609.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzGKEKbjPm06tAhnuCVc1v488kg3sFTWWzcrg-rt5pTKENdqXLPHCtrOtL7HjXR55yNf8QAsLwdwXTkCO1DikVEHowiIrEwQoSbT5VW27NOHUtIumMFI9feuP6kAddpE4cUXcmLZt1CrXP/s1600/IMG_20141121_214717609.jpg" height="320" width="180" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIY4nzIDXsFErJLeXl3soBZPPCgOhiOJv-TQ4m8VzS7fKX7SRUzIo5jHHOBRSD7tnMjpMHYKXuedVlve1s5m_UzHrEJTG0J5XceNMvZ1en3FtP8uBBubLHypZSsZRXMTDgHQrhK4yWVpks/s1600/IMG_20141121_214809768.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIY4nzIDXsFErJLeXl3soBZPPCgOhiOJv-TQ4m8VzS7fKX7SRUzIo5jHHOBRSD7tnMjpMHYKXuedVlve1s5m_UzHrEJTG0J5XceNMvZ1en3FtP8uBBubLHypZSsZRXMTDgHQrhK4yWVpks/s1600/IMG_20141121_214809768.jpg" height="320" width="180" /></a><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1kfwYAUYfuviF7ULdcP_cGdJ9hCu4Dl4QS49Oeeq24AAi5jI93_JOVz_rLQeGlzsbNfT1-7GI_laIGJtR2X9FhPRI9Qz90HmoKiZ4LXCKtOCi090TCbmutA2_CxIYalEcpLXmBmJxDfbZ/s1600/IMG_20141121_220744577.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1kfwYAUYfuviF7ULdcP_cGdJ9hCu4Dl4QS49Oeeq24AAi5jI93_JOVz_rLQeGlzsbNfT1-7GI_laIGJtR2X9FhPRI9Qz90HmoKiZ4LXCKtOCi090TCbmutA2_CxIYalEcpLXmBmJxDfbZ/s1600/IMG_20141121_220744577.jpg" height="180" width="320" /></a></div>
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First, I trimmed the fork down to the right diameter to fit the Llewellyn dropouts that I'm using. Then I used my home-made blade bender to add a nice smooth bend. The block was made for me by a coworker out of some scrap wood at his other job repairing boats.</div>
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I'm using <a href="http://www.henryjames.com/true-temper-27-6x20-oval-fork-blades-pair-27.html" target="_blank">1.0/.66 True Temper blades</a>. As a Dangerous Amateur (tm), I really like these. They bend easily and are pretty forgiving when I have to mess with them. The folks at Henry James are always a pleasure to work with, and if I mess up I can get replacements pretty quickly.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaEvPEsqsTbaaPsQT7Y01Ec-LVd0R_uPZ5510IbA3WG74spnXV5j6Ih6UU-X3mI0GV5oclsr1Qs9CWim7bh4bGR8nvh2KVShsH4xamS6gzbILl0yXGM07IVeAn27SujTQiBGyPWqyPa7tZ/s1600/IMG_20141121_214745701.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaEvPEsqsTbaaPsQT7Y01Ec-LVd0R_uPZ5510IbA3WG74spnXV5j6Ih6UU-X3mI0GV5oclsr1Qs9CWim7bh4bGR8nvh2KVShsH4xamS6gzbILl0yXGM07IVeAn27SujTQiBGyPWqyPa7tZ/s1600/IMG_20141121_214745701.jpg" height="320" width="180" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMvuYiYdKS0OfWngms1QagR8IXtapdzwOCOgxhh4Q7KgdPe9LgpywP-pQ1NWldwDVV5WhEXRp7dSbNiUtXsW0s0_fCUnc9mzFK7m2ctMveRo8ockRIebsaOdfLLi8_0GknTVORqfV7EKpB/s1600/IMG_20141121_214752535.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMvuYiYdKS0OfWngms1QagR8IXtapdzwOCOgxhh4Q7KgdPe9LgpywP-pQ1NWldwDVV5WhEXRp7dSbNiUtXsW0s0_fCUnc9mzFK7m2ctMveRo8ockRIebsaOdfLLi8_0GknTVORqfV7EKpB/s1600/IMG_20141121_214752535.jpg" height="320" width="180" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNmvBvSSDBigxpFsPwBXBUKxGqrbMOXhMetarowGyXnqi6Ov3LMEg_1e2kfDJm9_mqULQ65aVyeZrhwphKkY73OHmEOv9QtR01Qk9tYHwHJMW-aCmNF42W2D-jp6UVixz-cJ9TJEQAoa_F/s1600/IMG_20141121_221356592.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNmvBvSSDBigxpFsPwBXBUKxGqrbMOXhMetarowGyXnqi6Ov3LMEg_1e2kfDJm9_mqULQ65aVyeZrhwphKkY73OHmEOv9QtR01Qk9tYHwHJMW-aCmNF42W2D-jp6UVixz-cJ9TJEQAoa_F/s1600/IMG_20141121_221356592.jpg" height="180" width="320" /></a></div>
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48.5 mm rake on both blades, perfect! The bends are also pretty close to perfectly in-plane. Next step, fire!</div>
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For this bike, I have my own brazing setup. It's oxy/propane, and the oxygen is drawn from the air by a medical oxygen concentration. This way I don't have to deal with oxygen tanks or acetylene, and the slightly more diffuse flame that the propane makes actually feels a lot more natural for silver brazing.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZCPfbTCALQeRRN12JLb1dfxfa4j851BV7WUzUW4h4_6iJrzLP9a7w6CyBHpF_pQEW5NSsoEmG23Is5CtlyT928buRxel7XIDLPgJWvDSdrEWl0Wj5eODi-49Yy2ZJcZ1CK8jsEF_bmQTn/s1600/IMG_20141122_160715446.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZCPfbTCALQeRRN12JLb1dfxfa4j851BV7WUzUW4h4_6iJrzLP9a7w6CyBHpF_pQEW5NSsoEmG23Is5CtlyT928buRxel7XIDLPgJWvDSdrEWl0Wj5eODi-49Yy2ZJcZ1CK8jsEF_bmQTn/s1600/IMG_20141122_160715446.jpg" height="320" width="180" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJgklDWWUCtV5s45zXJv5BsPo7Pzf_Ix6c-oEqhwYfzJy0Bm_DECfJj4VZWo7rJt1HrBmBYoY1zLXrMJtA9ba5Lb8FKuB4QyG6gva8sMPwqCE7223A2AhbqN4wpkBr55xMHkHLlrj-ilx4/s1600/IMG_20141122_160723600.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJgklDWWUCtV5s45zXJv5BsPo7Pzf_Ix6c-oEqhwYfzJy0Bm_DECfJj4VZWo7rJt1HrBmBYoY1zLXrMJtA9ba5Lb8FKuB4QyG6gva8sMPwqCE7223A2AhbqN4wpkBr55xMHkHLlrj-ilx4/s1600/IMG_20141122_160723600.jpg" height="320" width="180" /></a></div>
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I started by attaching the fork crown to the steerer tube. I've gotten a lot more patient with practice and have stopped burning much flux. I pulled through some excess silver, but a swipe or two with a stainless steel brush while it was still hot got rid of most of it. The rest should come off in a few minutes with emery cloth.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihO5zyeViog0IMg7kfWyp3fTRJzZvAQJannOmkApmxjHel9zSiGndhuBjmQr54vrWSXyYoPHuQQ6-wSa9ay8oQlbaL0XA1NCqa510z8p2wIxqHhQptJc_he9aDC4jnb_gtJsUsQ7M7oVaz/s1600/IMG_20141122_160827594.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihO5zyeViog0IMg7kfWyp3fTRJzZvAQJannOmkApmxjHel9zSiGndhuBjmQr54vrWSXyYoPHuQQ6-wSa9ay8oQlbaL0XA1NCqa510z8p2wIxqHhQptJc_he9aDC4jnb_gtJsUsQ7M7oVaz/s1600/IMG_20141122_160827594.jpg" height="180" width="320" /></a></div>
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I didn't have time to start brazing the dropouts onto the fork, but I did spend a little time adjusting the jig. I bought it from someone who'd already adapted it to accept an anvil axle, and with a few extra measurements, it turns out pretty awesome results.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqWnWPEdpbxunWe4hLM6ApSVOn0DYfKpIjd2npA4fOR5r80vnsT4O_jdbshn2tFClVZ1Bzoj004K4Qnh_4dokvNrNQqCobbVRaeUSqJPDNdEsO1iDhLhyphenhyphen3KDzEtPW-_DeQTWDCMfw36bKB/s1600/IMG_20141120_165244133.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqWnWPEdpbxunWe4hLM6ApSVOn0DYfKpIjd2npA4fOR5r80vnsT4O_jdbshn2tFClVZ1Bzoj004K4Qnh_4dokvNrNQqCobbVRaeUSqJPDNdEsO1iDhLhyphenhyphen3KDzEtPW-_DeQTWDCMfw36bKB/s1600/IMG_20141120_165244133.jpg" height="320" width="180" /></a></div>
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Ok, it's been a while since I've written an entry, so I'm out of practice. Please accept this blurry picture of a puppy I want to adopt as a show of contrition.</div>
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Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-85216907609298108912012-06-30T23:37:00.000-07:002012-06-30T23:53:27.765-07:00Making Stays<div class="separator" style="clear: both; text-align: left;">
The seat stays connect the dropouts for the rear wheel to the junction of the seat and top tubes. On the dropout end, I attach a cap that slots into the rest of the dropout. The inside of the cap has some curves to it, so I started by filing the stay to match. I used calipers to determine the maximum distance that it could sink in, then measured that on the stay each time I made an adjustment.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG47CIj9BDUhq8Sr1jko88rUveeyI63vRkin63iIxeT9jgQr1Btv6j_fKfGLQJ-qAhaG7tgB9N1YR2vEQYprG2c1fjNXCEZyTOHG6PdYL7eOpfWtIjcI-g6QCYb9Ry790AIvVWhkWUV580/s1600/CameraZOOM-20120522235525011.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG47CIj9BDUhq8Sr1jko88rUveeyI63vRkin63iIxeT9jgQr1Btv6j_fKfGLQJ-qAhaG7tgB9N1YR2vEQYprG2c1fjNXCEZyTOHG6PdYL7eOpfWtIjcI-g6QCYb9Ry790AIvVWhkWUV580/s320/CameraZOOM-20120522235525011.jpg" width="240" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOSTO5-cAuze240mJ1_328Ldsye9pAHDlzmq0pyjs5LhI4qNiPntVc8nkWTOLyYlLaaZbjJhUyAnF9NrZTBQ0kzCwHrzj3Sa6IerI0MEBeVBCXBXYYM98j20-fgG67JY0lhr_JkPVAtAjd/s1600/CameraZOOM-20120515223519907.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOSTO5-cAuze240mJ1_328Ldsye9pAHDlzmq0pyjs5LhI4qNiPntVc8nkWTOLyYlLaaZbjJhUyAnF9NrZTBQ0kzCwHrzj3Sa6IerI0MEBeVBCXBXYYM98j20-fgG67JY0lhr_JkPVAtAjd/s320/CameraZOOM-20120515223519907.jpg" width="320" /></a></div>
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Now, since the cap doesn't have a second open end, I had to do things a little differently to see if I'd filled everything properly. If I were a pro, a blind braze like this wouldn't make me blink, but I'm still a bit paranoid. On the suggestion of the internet, I curled up a little plug of silver, coated it in flux, and dropped it in the cap. Then I added the stay and heated the whole end until the silver melted and was sucked up into the joint by capillary action.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKbXUO_2OvkH7-J7d3xbXGiMa2fYnWuiq90cgVIN3VRLK9IaklUcacotfW3xBEAat-wfGzLjN8xEKWzE3ksuqNDTnQk20WaWC46vchob0kzTJXoTntyAl3jckVp715uO2aZflBk5_Dylyt/s1600/CameraZOOM-20120515225301085.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKbXUO_2OvkH7-J7d3xbXGiMa2fYnWuiq90cgVIN3VRLK9IaklUcacotfW3xBEAat-wfGzLjN8xEKWzE3ksuqNDTnQk20WaWC46vchob0kzTJXoTntyAl3jckVp715uO2aZflBk5_Dylyt/s320/CameraZOOM-20120515225301085.jpg" width="240" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6_rB39DeKkGOQYCrwZQOhTjESe2HojTSG8xdp6wvLUY8b1vhc_uQ0-1BoZRZg_Py4txm2D5Fxgk6k27R7t4M50K-0yVGhjLqt2AxJ0EZNyPZNq_uPod3N_g_nhkfnpmiAar5Z_pgGJ5Rk/s1600/CameraZOOM-20120629194839370.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6_rB39DeKkGOQYCrwZQOhTjESe2HojTSG8xdp6wvLUY8b1vhc_uQ0-1BoZRZg_Py4txm2D5Fxgk6k27R7t4M50K-0yVGhjLqt2AxJ0EZNyPZNq_uPod3N_g_nhkfnpmiAar5Z_pgGJ5Rk/s320/CameraZOOM-20120629194839370.jpg" width="320" /></a></div>
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For the other end, I wanted to make an abrupt but rounded cap. <a href="http://curmudgeonbicycles.blogspot.com/2012/02/seat-stays-practice-1.html" target="_blank"> I've already done this, so it didn't hold a lot of surprises.</a> It was a bit harder than last time because I spaced on drilling vent holes before brazing the end up. That leaves heated air trying to push the filler out. It worked out alright, but I'll be more careful next time. I used brass so that the filler wouldn't melt when I braze them to the sides of the seat lug.<br />
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Also note that I notched the lug itself to increase the surface area that will hold things together.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_s2q6X0LpQ5f5YvYa9wFmLLYXLnqlj6j-xvdcbKwyZRCQpXhzSbINs1HeTMWP0voKYlIYgAkAeYIXnjfRiZFNRgZd7UPXxWok63Iu7rdzxuz4mqSguLPtbZkzzhhwbfEIGO3bDwGqA4Us/s1600/CameraZOOM-20120623155640713.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_s2q6X0LpQ5f5YvYa9wFmLLYXLnqlj6j-xvdcbKwyZRCQpXhzSbINs1HeTMWP0voKYlIYgAkAeYIXnjfRiZFNRgZd7UPXxWok63Iu7rdzxuz4mqSguLPtbZkzzhhwbfEIGO3bDwGqA4Us/s200/CameraZOOM-20120623155640713.jpg" width="150" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgBIyHyzxD2QqRHoFb0vfvGwAMrzwGxxj4k89wTkOsGZ-3rjHZ_S0fJyec9FerYn2qTlw0mC8_4VPY1yoy5Xt5AFKA4ibb_x5spu6dvF_vku3wFrHcMN1gpMmphgVR38AQUGAHAx-Kzw27/s1600/CameraZOOM-20120625223244086.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgBIyHyzxD2QqRHoFb0vfvGwAMrzwGxxj4k89wTkOsGZ-3rjHZ_S0fJyec9FerYn2qTlw0mC8_4VPY1yoy5Xt5AFKA4ibb_x5spu6dvF_vku3wFrHcMN1gpMmphgVR38AQUGAHAx-Kzw27/s200/CameraZOOM-20120625223244086.jpg" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhF72W2JaVR3IKb6bxO-hPXwUuJ5Lq7PkMndV2iz4pT-t4OgRvpN9LNaSSGC9bDQdtbeAjJLvvb__TZU5Z5YFnTcIhlUNuW2-amZT2xUFgvilt38BwMKNbRanLDODn7VHCigqgjnzZvGYq4/s1600/CameraZOOM-20120626224612517.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhF72W2JaVR3IKb6bxO-hPXwUuJ5Lq7PkMndV2iz4pT-t4OgRvpN9LNaSSGC9bDQdtbeAjJLvvb__TZU5Z5YFnTcIhlUNuW2-amZT2xUFgvilt38BwMKNbRanLDODn7VHCigqgjnzZvGYq4/s200/CameraZOOM-20120626224612517.jpg" width="200" /></a></div>
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The dropout caps go on the chainstays in about the same way as they go on the seat stays, but you have to line them up so that they're in the same plane as the oval in the stay.Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-26060502344565189222012-06-24T16:03:00.000-07:002012-06-24T18:29:57.021-07:00Front Quadrilateral<br />
<b>FINALLY</b><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5x65erytbHGZoq8DSzFaYZ130FLJkUkANiXHebbmlliRsCa0h5JtKQsMMHDHme6CcV6vnFxsr9J0Qjx4Ztha5PnST0TPFBFltPXcBFPFzyoJMM-Pc5GTEF0qB3BpfIa0s-x_p08D6jy7b/s1600/CameraZOOM-20120609185130304.jpg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5x65erytbHGZoq8DSzFaYZ130FLJkUkANiXHebbmlliRsCa0h5JtKQsMMHDHme6CcV6vnFxsr9J0Qjx4Ztha5PnST0TPFBFltPXcBFPFzyoJMM-Pc5GTEF0qB3BpfIa0s-x_p08D6jy7b/s320/CameraZOOM-20120609185130304.jpg" /></a></div>
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And, at long last, I have a nice big chunk of the bike done. The front triangle (quadrilateral to all of you literal minded geometrists) is a unit now. </div>
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I started by getting the jig set up. I used my little angle gauge to determine that all of the tubes were in plane and clamped stuff in place. Unfortunately, I discovered that the cold set I'd done earlier hadn't actually taken, and was unable to get the down tube/head tube junction at exaclty the right angle. This will make the bike a bit shorter (I trimmed the down tube based on how things fit together before I realized what was going on), and make the seat tube angle a lot slacker. I may have to shove my seat forwards a bit, but it'll still be rideable. Summary: I messed up a fair amount but I think I'll still be able to ride it with pleasure until bike #3 rolls around in a few months to replace it (#2 will be a single speed to take the place of an existing steed).</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJYkNenARyZm2L3ChEK_Ze0d_eNhgP8sgHnB-MLzt7VJ03wvHuqXikVbNh2Ln4Rdgou7p3SXorL7YEPIDO0QQpCDGL8atc9rb8Rq2PeEa8emuSHu7bM2RFONlKht1iB45uhVRvJ17Hhovn/s1600/CameraZOOM-20120609172410822.jpg" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJYkNenARyZm2L3ChEK_Ze0d_eNhgP8sgHnB-MLzt7VJ03wvHuqXikVbNh2Ln4Rdgou7p3SXorL7YEPIDO0QQpCDGL8atc9rb8Rq2PeEa8emuSHu7bM2RFONlKht1iB45uhVRvJ17Hhovn/s320/CameraZOOM-20120609172410822.jpg" /></a>Next, I tacked the down tube to the bottom bracket and layed it out on the alignment table. The big block you see is a theater weight. It's heavy enough that it pins the plane of the bottom bracket shell to the table. Then I just drag a height gauge around to see if the tubes tip one way or another.
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It took a lot of tweaking, but I got it in plane. At one point a tack popped and nearly made me jump out of my skin, but it didn't damage anything and I just melted it back together. </div>
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I don't have pictures of the actual process because it happened all in one big rush. I basically powered through right before the shop closed. It was pretty uneventful and predictable. I was nervous, so my brazes weren't the best, but they'll do. The only big hiccup was putting a hand down to steady myself while peering into the bottom bracket looking for filler and burning a hole through my shorts with the still hot brazing rod.</div>
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Fear not, no genitals were torched in the building of this bike.
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWlRdGOqNFvQxXcd6Zdvx-IysWHWoAXxdghKRHWqkZvOIIcF6vVbnNixWBCDrX-KkoeKcgI1tD3_m01KP6eA1pDt2RgykdNG10vL6l5STwF0zORFygG8FJV8w7cWvzFPBN9lvfmT-_V7jy/s1600/CameraZOOM-20120609231835004.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWlRdGOqNFvQxXcd6Zdvx-IysWHWoAXxdghKRHWqkZvOIIcF6vVbnNixWBCDrX-KkoeKcgI1tD3_m01KP6eA1pDt2RgykdNG10vL6l5STwF0zORFygG8FJV8w7cWvzFPBN9lvfmT-_V7jy/s400/CameraZOOM-20120609231835004.jpg" width="400" /></a></div>
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When I checked the alignment, I found that it was fair, but not perfect. I'm pretty happy with it as a first attempt and will make better alignment a big goal on bike #2.</div>
</div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-6320044527112764902012-06-04T00:13:00.000-07:002012-06-04T00:13:35.909-07:00Getting Bikey<div class="separator" style="clear: both; text-align: left;">
<b>Braze-ons</b></div>
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The braze-ons went on pretty quickly this time, except for one brake stop that kept moving around. Ended up with about a metric ton of silver on there. I'll have to get some little magnets. The one I used to hold things still for a couple of other bits worked well, but I managed to ruin it with the flame. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNovnqvkzxwkApIuCENreXm1kyd-qlmClxoI6AH7pvZ1k19hnzxFdc76Sji9iDmE4KrKmzlaaSkdfPPdhdYzUB-PrE-34vdt8ziIzKzAI01KPXEQI69_JDonrbREQEhCIiwEdXpFRplosA/s1600/CameraZOOM-20120602154108917.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="200" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNovnqvkzxwkApIuCENreXm1kyd-qlmClxoI6AH7pvZ1k19hnzxFdc76Sji9iDmE4KrKmzlaaSkdfPPdhdYzUB-PrE-34vdt8ziIzKzAI01KPXEQI69_JDonrbREQEhCIiwEdXpFRplosA/s200/CameraZOOM-20120602154108917.jpg" width="150" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqXwh-6N7rAJrbNBmkp62IlT7zWF-zDPjI5MI_xLU4EhWXtc8U-9YQ7SGZetp3D6clldOYH6KdlvbT2zKEqehN-IHYHdXwnAsgcjofi9qs0FJLnzRbSzdn5yYgxrrK59wK1ZNYn1QNXpfK/s1600/CameraZOOM-20120602153943423.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqXwh-6N7rAJrbNBmkp62IlT7zWF-zDPjI5MI_xLU4EhWXtc8U-9YQ7SGZetp3D6clldOYH6KdlvbT2zKEqehN-IHYHdXwnAsgcjofi9qs0FJLnzRbSzdn5yYgxrrK59wK1ZNYn1QNXpfK/s200/CameraZOOM-20120602153943423.jpg" width="200" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjp3vzrYCh4z25I4k2ugqc7zeO0mJ9nLpMrIUDARlAVh8Zr7kjdwCH27nRguuwsYgaeEfedZTZ1Ui3QJ1XymwvwdleqxPEZ-zRY0Jzzwk0QyyAnV2jRlZ8iY4cr5TZSGW0nCYPcIT9EiHjA/s1600/CameraZOOM-20120526192210646.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjp3vzrYCh4z25I4k2ugqc7zeO0mJ9nLpMrIUDARlAVh8Zr7kjdwCH27nRguuwsYgaeEfedZTZ1Ui3QJ1XymwvwdleqxPEZ-zRY0Jzzwk0QyyAnV2jRlZ8iY4cr5TZSGW0nCYPcIT9EiHjA/s200/CameraZOOM-20120526192210646.jpg" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiF8Lx-9FwsaJdphycO1bLKw1QD5cbm1BEtGSNIsBE1t7ev6oFMSu7bL5BNkvENV8GoiXf5Gbh6YfB3bTggHeKuHFe8RIppH7ecY82L49KQ16SnaFYTz56zKg7xKA40_GsMGLiuYWw4BAm/s1600/CameraZOOM-20120526192307063.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiF8Lx-9FwsaJdphycO1bLKw1QD5cbm1BEtGSNIsBE1t7ev6oFMSu7bL5BNkvENV8GoiXf5Gbh6YfB3bTggHeKuHFe8RIppH7ecY82L49KQ16SnaFYTz56zKg7xKA40_GsMGLiuYWw4BAm/s200/CameraZOOM-20120526192307063.jpg" width="200" /></a></div>
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<b>Head Tube/Down Tube Sub-assembly </b><br />
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I didn't get a lot of photos of my first joint on this attempt, as my phone ran out of batteries pretty early on. Luckily, it was pretty simple. I checked the angles, fluxed it up, and brazed it. I did burn some flux on the head tube side of the joint, right at the bottom. Thankfully, after I chipped off the burnt flux and spread around some fresh, I was able to channel enough silver through to feel pretty confident about the joint.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRfDHSg2AZZ5Nop3Bc7l_s9twXLegxDTQ-nfL-PVBtCzfMqyT217_yvWs_rH9KMh0FhP4CFCMLWeYx0zKUKPxNjZChXWIgXXLqI64jdPJqV5aoS5HLCH5VOhCF4beqwxz16MpWcNvPYSrW/s1600/photo.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRfDHSg2AZZ5Nop3Bc7l_s9twXLegxDTQ-nfL-PVBtCzfMqyT217_yvWs_rH9KMh0FhP4CFCMLWeYx0zKUKPxNjZChXWIgXXLqI64jdPJqV5aoS5HLCH5VOhCF4beqwxz16MpWcNvPYSrW/s320/photo.jpg" width="320" /></a></div>
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Despite being pretty careful, it seems that the joint pulled back to the original 60 degree angle of the lug, not to the 59.3 that I'd thought I'd filed things to. It only took a few minutes with a cheater bar through the head tube to make the adjustment, and I managed to finish it out within .1 degrees of correct. </div>
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<i>The above picture was taken after some sanding and filing.</i></div>
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<b>Seat Tube/Bottom Bracket Sub-Assembly</b></div>
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I was worried going into brazing the bottom bracket shell on to the seat tube. The BB is a big heavy piece of steel, and that makes it a lot harder to get up to temperature without going over. I did a test joint right before doing the actual work, just to get myself calibrated. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbuntQ7RCP6RIFQwCwhLNRlxb4Bo-e-jt2TphOce62VMtvWjxo5P-DblUTZ9_OHdYPWPxkyqyKvY_TtB2nUCkEaSDmTXH6ZyDwsjzf5lvkukGD_DdQystN3jWrP39HU-Q6BLruwIO1Vo-B/s1600/CameraZOOM-20120602183444762.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbuntQ7RCP6RIFQwCwhLNRlxb4Bo-e-jt2TphOce62VMtvWjxo5P-DblUTZ9_OHdYPWPxkyqyKvY_TtB2nUCkEaSDmTXH6ZyDwsjzf5lvkukGD_DdQystN3jWrP39HU-Q6BLruwIO1Vo-B/s320/CameraZOOM-20120602183444762.jpg" width="320" /></a></div>
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<i>The test piece came out pretty well, a nice clean ring of silver in each of the cross sections.</i></div>
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When it was time to do the joint itself, I got everything aligned and fluxed, then tacked the front and back of the BB lug to keep it in place, then aligned everything again. When I started brazing, it worked flawlessly. I was able to draw the silver exactly where I wanted it. Best braze I've done to date... until I got half way and the BB fell right off. It was comic, and frustrating. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXdsAedH6qJwRZOFOkA-P2qc_32CuTOU_5ScZkTOfQceyo4rlf27Ioz2I-z77X2F4G0hWGP4R1Le1CgbbfUlRgpS4JXugLVXRH-5uStx47ieIB1FpQNdwMAWIOmPwlj6L-ZDHdSFX0tJ2g/s1600/CameraZOOM-20120602184322809.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXdsAedH6qJwRZOFOkA-P2qc_32CuTOU_5ScZkTOfQceyo4rlf27Ioz2I-z77X2F4G0hWGP4R1Le1CgbbfUlRgpS4JXugLVXRH-5uStx47ieIB1FpQNdwMAWIOmPwlj6L-ZDHdSFX0tJ2g/s320/CameraZOOM-20120602184322809.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKrDtOXOZFbi26VGpA_dMuh8dos193epY0Mu6orfPqNDHZLX5o39Q0jvk-9qVqaa6hMuahjkWqm_BYLKFMX2wp_QRqbOPNPlIaSrdiEUEplT4uLchGqmRLbm70GsfwumHc7o5kM8iHbcy8/s1600/CameraZOOM-20120602194808766.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKrDtOXOZFbi26VGpA_dMuh8dos193epY0Mu6orfPqNDHZLX5o39Q0jvk-9qVqaa6hMuahjkWqm_BYLKFMX2wp_QRqbOPNPlIaSrdiEUEplT4uLchGqmRLbm70GsfwumHc7o5kM8iHbcy8/s320/CameraZOOM-20120602194808766.jpg" width="320" /></a></div>
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Basically, I'd had about half the shell up to temperature, so all of the silver was soft at the same time. On my second try (after soaking and sanding each surface clean), I tacked the piece on four sides. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjma8uYHOpucn7hIIFGbCb22OTa8wCRSqAL4n5iY4v24_oJOndMbP_oD5GFJy7Z5LAYsUND0-VKMM3525Gv-f0qsnYG4yABo26KMKWSJD3_U2Q30rYbHevg2c1nN4SBuriKtc8rvF6nDECF/s1600/CameraZOOM-20120603143351902.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjma8uYHOpucn7hIIFGbCb22OTa8wCRSqAL4n5iY4v24_oJOndMbP_oD5GFJy7Z5LAYsUND0-VKMM3525Gv-f0qsnYG4yABo26KMKWSJD3_U2Q30rYbHevg2c1nN4SBuriKtc8rvF6nDECF/s320/CameraZOOM-20120603143351902.jpg" width="320" /></a></div>
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This time it worked almost as well, but with less falling. I used WAY too much silver, in my paranoia about gaps or voids, but that's easily fixed with emery cloth and patience. I didn't even overheat things much!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOtxKCaYnFgqdNOrK2Ehy9gII8jB6ynjFv0kPzG2YwCFDktxfX1PbqOsL8BsLuH0R-wX1y6rycQKKpK_AoNBNr9pREyvW2CBubcXXaNF2S-CA8t3dFfzd70v7qas0myKKXC9jt9NyAS-1c/s1600/CameraZOOM-20120603151336301.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOtxKCaYnFgqdNOrK2Ehy9gII8jB6ynjFv0kPzG2YwCFDktxfX1PbqOsL8BsLuH0R-wX1y6rycQKKpK_AoNBNr9pREyvW2CBubcXXaNF2S-CA8t3dFfzd70v7qas0myKKXC9jt9NyAS-1c/s320/CameraZOOM-20120603151336301.jpg" width="320" /></a></div>
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I did find that the points were a bit far from the lug, as I'd widened the socket to get the angles right (this tube needed to tilt about 1 degree further in the direction of the down tube than the lug is set up for). If I'd been thinking more, I'd have clamped the points back into place before proceeding. As it is, I'll just have to dribble a bit more filler on the point when I do the other joints and sand until it doesn't look dumb. Internally, it should be fine.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8Ux-KwOeL-bWlvkDE5kGnib9-FKH2QUtLrgLDV78859wnD9JmJ6UY4T0vyw1NsvHUsCsajIOw4B7axJB-l_-J1GdyD1PfF4WFNS0hOfQLQMUFr9-UYLuslFtkFtvQnJf_3RPEQ8QIWDzV/s1600/CameraZOOM-20120603175354611.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8Ux-KwOeL-bWlvkDE5kGnib9-FKH2QUtLrgLDV78859wnD9JmJ6UY4T0vyw1NsvHUsCsajIOw4B7axJB-l_-J1GdyD1PfF4WFNS0hOfQLQMUFr9-UYLuslFtkFtvQnJf_3RPEQ8QIWDzV/s320/CameraZOOM-20120603175354611.jpg" width="320" /></a></div>
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Just for fun, I slotted the two sub-assemblies together and was overjoyed to find out that, if I don't let stuff slip when I braze the last few joints, the vertical tubes should both end up at the required 73 degrees.</div>
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<i>Funny story: </i></div>
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<i>I had to cold set</i><i> (fancy term for "bend") the </i><i>BB's angle, after tacking but before brazing. When I cranked the tube to the side a degree or two, one of the little tacks popped free. I must have jumped a few feet into the air, and was sure that I'd wrecked the whole thing.</i></div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-22398793292644921272012-05-27T01:24:00.002-07:002012-05-27T01:25:22.168-07:00Mitering!I just finished preparing the new tubes for my main triangle. This time around, I marked the center lines a little differently than <a href="http://curmudgeonbicycles.blogspot.com/2012/01/center-lines.html" target="_blank">last time</a>. Instead of using a Sharpie to mark the center of the tube, I slathered it in layout fluid (a kind of easily removable paint) and dragged the height gauge along it. That left a nice clean silver track through the coat of blue. It was a much finer line than the sharpie left, quicker to place, and more accurate.<br />
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I also re-<a href="http://curmudgeonbicycles.blogspot.com/2012/01/ignore-this-boring-post-about-butts.html?" target="_blank">measured the butts</a> on the tubes, as I'd swapped a couple of them out for new ones. I'm glad I was careful; one of the tubes had the thinned section shifted about 30 mm towards one end. <br />
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I'm using some guidelines recommended to me by a talented builder (who coincidentally designed the slant-six lugs that I'm using) about the location of the butts and lugs. He said that I should make sure that the lug tips don't come closer than 20mm from the end of the butt on the top tube and 40mm on the downtube. There's not a ton of agreement about how much of a safety margin is necessary, but I think that it makes good sense for me to err on the side of caution for this first bike.<br />
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I marked the tubes at the end of the butt and at the beginning of the "safe area" to avoid confusion.<br />
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<b>Mitering</b><br />
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Mitering is when you cut the "fishmouth" into one tube that lets it rest flush against another tube (the base tube) at a specific angle. Figuring out where to cut can be tricky. Luckily, Nova (where I buy my tubes) has a great little app <a href="http://www.cycle-frames.com/bicycle-frame-tubing/Tabbed-Tube-Notcher.html" target="_blank">on their site</a>.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx5lz-T3CjbZilZPue0U9shqynNrsZ2G5h2W0tpjZj5l3dD2qz9ZOqlyEMlqpDztIpexMszB-mDLacZ2FLz0hVAnj12hiOkq7M9yzxty1KOFU3H3qzuk5aEpgFZrRsxv8BoNKxuDUMq9WZ/s1600/CameraZOOM-20120525232028383.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx5lz-T3CjbZilZPue0U9shqynNrsZ2G5h2W0tpjZj5l3dD2qz9ZOqlyEMlqpDztIpexMszB-mDLacZ2FLz0hVAnj12hiOkq7M9yzxty1KOFU3H3qzuk5aEpgFZrRsxv8BoNKxuDUMq9WZ/s320/CameraZOOM-20120525232028383.jpg" width="240" /></a></div>
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After you set the tube sizes and angles, the app gives you a printout that you can cut out and tape around the tube in question. By lining up the center lines of the printouts with the center lines on the tubes, you ensure that everything is in the right plane. Even better, you get a reference line that helps you space the patterns out. In this case, the square end of the paper is 101mm from the center point of the base tube. If you take the total distance from one intersection to another and subtract the offsets from both of the templates, it gives you how far apart they need to be.<br />
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I roughed out each miter with a Dremel, then knocked off the last few mm with a half-round file. That kept me from going too far or heating the paper until it browned, which makes it hard to see what's going on. Notice that the template has two cut-lines on it. One represents the outside of the tube, the other represents the inside. This helps you figure out which way the edge of the tube should be slanted, and how much. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWQsC_jSJz9JBeucBSs97IVnVY-WWuz5gWozLCLtuZxjTNx1OXgmNdgRbuwKioPhOImkRsNR9dUyj8X_3WIYXRkTIU9dLqQmj-s62-mRbhxJnjj_dDKnsfRsK1TVFlGC3lpnwoHmCl_pwZ/s1600/CameraZOOM-20120526243240593.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWQsC_jSJz9JBeucBSs97IVnVY-WWuz5gWozLCLtuZxjTNx1OXgmNdgRbuwKioPhOImkRsNR9dUyj8X_3WIYXRkTIU9dLqQmj-s62-mRbhxJnjj_dDKnsfRsK1TVFlGC3lpnwoHmCl_pwZ/s320/CameraZOOM-20120526243240593.jpg" width="320" /></a></div>
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<i>Note: When you join two tubes of the same size, it gives you a pretty huge "outside" line. This assumes that you can file the sides infinitely thinly so that they go all the way to the middle of the other tube. You can't. I just knocked mine down to a bit over the "inside" line.</i><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3erEgRfX3i8aEHe9rM-CuNOXmo6vnSmMwNIslKNrHRvEIJK3AoENn3gJjBAxOGLQYerFMsDMsECfzWf3kFUxYKJTIEkuFSVrFAnLc_tr0Y_laaao_21iaCTJdPs2M1onMfXH-WdYGiKPm/s1600/CameraZOOM-20120525232005688.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3erEgRfX3i8aEHe9rM-CuNOXmo6vnSmMwNIslKNrHRvEIJK3AoENn3gJjBAxOGLQYerFMsDMsECfzWf3kFUxYKJTIEkuFSVrFAnLc_tr0Y_laaao_21iaCTJdPs2M1onMfXH-WdYGiKPm/s320/CameraZOOM-20120525232005688.jpg" width="320" /></a></div>
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I finished each miter by wrapping the corresponding base tube in sand paper and dragging it through, taking care of any remaining little issues. Then I balanced the base tube on top of the miter and checked the angles of both tubes with my little <a href="http://www.amazon.com/Wixey-WR300-Digital-Angle-Gauge/dp/B001PTGBRQ/ref=sr_1_1?ie=UTF8&qid=1338105861&sr=8-1" target="_blank">Wixey Angle Gauge</a>. In one case I was within .1 degree of the correct angle on the first try. With the others I had to do a bit more filing to touch it up. </div>
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This weekend I should be able to finally start brazing my front triangle!</div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-87219802498019647262012-05-12T19:24:00.000-07:002012-05-12T19:26:55.658-07:00Brazing Interlude Part Duex<div class="separator" style="clear: both; text-align: center;">
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<b>Sleeve</b><br />
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I started today working on another fake-lug practice piece. I used a bit too much silver, but it filled nicely and turned out well. Pretty close to perfect. I just need to keep the heat down a bit to avoid crispy flux.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdH9F3D6931NFKpYQb435HDCxo22Inb_qjyGOh47n_edquqS7dIGgT9Afg7YvvXLCu0cWeEgYiKHkcrqt7X-uiDLAnVKMrO4jjpDLJhWHmtrRYWd1v2BZrZA8w5rc2NH79BRp8TcvDmoUY/s1600/CameraZOOM-20120512160304839.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdH9F3D6931NFKpYQb435HDCxo22Inb_qjyGOh47n_edquqS7dIGgT9Afg7YvvXLCu0cWeEgYiKHkcrqt7X-uiDLAnVKMrO4jjpDLJhWHmtrRYWd1v2BZrZA8w5rc2NH79BRp8TcvDmoUY/s320/CameraZOOM-20120512160304839.jpg" width="320" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRLfuv7el3ZxbFqdoCVkd-aqbB5gocKOWfrl7U0crL5IUfNCK3aq3HGBwaijSW4fOAjK80v3D7q0s58SNyi34pb7wgznOnHTkZ83l4G6HsbImBoWxdO6khbt374UlyVGZuTa22O-gJNwNT/s1600/CameraZOOM-20120512160312533.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRLfuv7el3ZxbFqdoCVkd-aqbB5gocKOWfrl7U0crL5IUfNCK3aq3HGBwaijSW4fOAjK80v3D7q0s58SNyi34pb7wgznOnHTkZ83l4G6HsbImBoWxdO6khbt374UlyVGZuTa22O-gJNwNT/s320/CameraZOOM-20120512160312533.jpg" width="320" /></a></div>
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<b>Seat Lug</b></div>
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I followed up the sleeve by brazing up the last investment cast lug from my initial lug/tubeset (the one that never really panned out). <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9SLs6Ntp0PmeiHGBj-Y21-TldShS92kjmkevkdZXmFZTsxA4Ugt7tfEKSBwI9VhBfCZQOyBVKL3O2aRBTnI00GcYWgSCiNU2I5NcOxk8BiIoFJ_p_sJRuxvaLYSm3xouh4ZVcu5fgxx55/s1600/CameraZOOM-20120512164603970.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9SLs6Ntp0PmeiHGBj-Y21-TldShS92kjmkevkdZXmFZTsxA4Ugt7tfEKSBwI9VhBfCZQOyBVKL3O2aRBTnI00GcYWgSCiNU2I5NcOxk8BiIoFJ_p_sJRuxvaLYSm3xouh4ZVcu5fgxx55/s320/CameraZOOM-20120512164603970.jpg" width="320" /></a></div>
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<span style="text-align: -webkit-auto;">This didn't turn out quite as well. I got the shorelines filled, and most of the higher stress areas, but </span>I wasn't able to fill the crease between the two tubes all of the way to the very center in a lot of places. The gap is pretty small, but I'll have to work on it a bit. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDHWOsWALSIju6EJCC0AR9uB0b6Z7WJ_oSbjutgJ4_N5Gh0tsdbikjcRxRGJqf-ka8MTeNqDvosfNT2T51p9g8wOCD76StTb28uvdUFbzAD6UD7rGn2mern32F7FLcv6x4gJ5L2VVluWeC/s1600/CameraZOOM-20120512170411813.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDHWOsWALSIju6EJCC0AR9uB0b6Z7WJ_oSbjutgJ4_N5Gh0tsdbikjcRxRGJqf-ka8MTeNqDvosfNT2T51p9g8wOCD76StTb28uvdUFbzAD6UD7rGn2mern32F7FLcv6x4gJ5L2VVluWeC/s320/CameraZOOM-20120512170411813.jpg" width="320" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcShDhlfP7Vej726MPZgUovX_INFbf7kA1ftRcrMzIz-h0LZ06sSR9BWbNXQzbnjqUGm9zMcbQ8mnknx2j3iJTZsKH9a7OpO83jDDZWYz5IM5kLtPdxV6CQuT-uJaS_4YYIsrVJKAGFaFm/s1600/CameraZOOM-20120512170430200.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcShDhlfP7Vej726MPZgUovX_INFbf7kA1ftRcrMzIz-h0LZ06sSR9BWbNXQzbnjqUGm9zMcbQ8mnknx2j3iJTZsKH9a7OpO83jDDZWYz5IM5kLtPdxV6CQuT-uJaS_4YYIsrVJKAGFaFm/s320/CameraZOOM-20120512170430200.jpg" width="320" /></a></div>
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I also had trouble getting the filler to flow under the "ears" at the back. The ears basically just clamp down on a seatpost, so it wouldn't be likely to cause a catastrophic failure... still, I'll have to start by getting them nice and hot next time.<br />
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My new lugset is thinner, but covers more area. The shorelines are also a lot smoother, no huge points coming from small joints. I think that'll help a lot when it comes to getting an even flow without overheating things.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaFEi7Rumi4-9bXLQkbv9GoM7qZfQ8XSyx7_DL4s92SPyANtfo8-nGClteaMVxCPw9KDrIa9fikWYAdHtmFV_wUcAw0DsLXcN-Kihozgz0MFtdOXE79PqxoV3PQyuR2OHgT89Sm7YzJ_7V/s1600/CameraZOOM-20120512171946832.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaFEi7Rumi4-9bXLQkbv9GoM7qZfQ8XSyx7_DL4s92SPyANtfo8-nGClteaMVxCPw9KDrIa9fikWYAdHtmFV_wUcAw0DsLXcN-Kihozgz0MFtdOXE79PqxoV3PQyuR2OHgT89Sm7YzJ_7V/s320/CameraZOOM-20120512171946832.jpg" width="320" /></a></div>
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Here's what's left after the autopsy!</div>
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<br />Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-43258987690847884832012-05-01T22:49:00.001-07:002012-05-01T22:49:33.168-07:00Brazing InterludeI'm taking a bit of time this week to remind myself that I'm not actually spending all this time JUST to make a bike rack. I went back to doing some practice brazes and found that the work on the rack had really helped. My heat control has improved, and perhaps as important, I'm a bit more patient and less jittery. <br />
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<b>Fake Lugs</b></div>
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I'm going to spend more time doing fake lugs before I waste more real lugs. I'm stealing this design from Andy on the forums (don't worry about which forums, he's all over the place). A lot of people use nesting tubes, but he cuts them at an angle, which both looks cooler and gives you a better feel for drawing the silver through varying distances on the same piece. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgXed0jNrLjq7MlTlG6Lq3MGiRB7HLxTjJ6LYrVN3gJM9ZHz8dTYeLIEevxZCh-7GiA21G2i8ujaOwwPuMr5AW91685HafAT0nFiKQVivFj74f2M-hLto08tdL4c1vRStYcRKFPspMOKKo/s1600/IMG_20120429_182717.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgXed0jNrLjq7MlTlG6Lq3MGiRB7HLxTjJ6LYrVN3gJM9ZHz8dTYeLIEevxZCh-7GiA21G2i8ujaOwwPuMr5AW91685HafAT0nFiKQVivFj74f2M-hLto08tdL4c1vRStYcRKFPspMOKKo/s640/IMG_20120429_182717.jpg" width="640" /></a></div>
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On the first run, I drew the silver through nice and cleanly. I overheated things a bit, but not too bad. The shorelines were pretty clean and would require minimum sanding. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr-xC8DsxJA6huY8-mNReiWzB3T8e2hLFbIf-Apyw7uJ9bcoLjST4eN6b-L4VuczDfPT4gBD1H6kDdcyD8Mvhwt5EGe0FLrMW_pemmkIesjWvWEm4Tj9LhEelLngZFKsYkOsZkoQFlqWWO/s1600/IMG_20120429_174804.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr-xC8DsxJA6huY8-mNReiWzB3T8e2hLFbIf-Apyw7uJ9bcoLjST4eN6b-L4VuczDfPT4gBD1H6kDdcyD8Mvhwt5EGe0FLrMW_pemmkIesjWvWEm4Tj9LhEelLngZFKsYkOsZkoQFlqWWO/s640/IMG_20120429_174804.jpg" width="640" /></a></div>
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When I cut it open, it looked just about perfect. This might be a bit misleading, since I cut it pretty low. It's possible that filler flowed around through that area when I touched up the shorelines by melting the very edge. My instinct, though, is that I used a light enough touch that this is accurate. </div>
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I did a second practice bit, and had a bunch of gaps. While disappointing, it gave me some valuable insight. On the first bit I was methodical and slower, on the second, I overheated things, and skipped around the tube by a third while it cooled and came back. I think it's pretty clear that I need to slow down and force myself to relax and move in a straight line. </div>
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<b>Breaking Ground</b></div>
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I just prepared the dropouts for the new frame by brazing on eyelets for a rack. I did it with brass, both because it's stronger than silver for this sort of joint and because it's higher melting temperature will keep it solid when I attach the chainstays and seatstays with silver.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieeVgFMcO2Mmem2XBNWZZPa2t_7qJlu-ILXaAILNieQyGw_dwbpSHq1DIdOpqPgSecmFovG4toj3XDN4_oniybE6dzeSHe1t0CMW8KbhqfWnk1qtbi-SVz6lI4fLzGNmvGPrkmApnF3mVF/s1600/IMG_20120430_005022.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieeVgFMcO2Mmem2XBNWZZPa2t_7qJlu-ILXaAILNieQyGw_dwbpSHq1DIdOpqPgSecmFovG4toj3XDN4_oniybE6dzeSHe1t0CMW8KbhqfWnk1qtbi-SVz6lI4fLzGNmvGPrkmApnF3mVF/s400/IMG_20120430_005022.jpg" width="400" /></a></div>
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<br /></div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com2tag:blogger.com,1999:blog-8638154953594434939.post-27629503715088376852012-04-28T17:52:00.002-07:002012-04-28T18:16:29.657-07:00Cargo Rack, Part 4In this series: <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-1.html">Part 1</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-2.html">Part 2</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-3.html">Part 3</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-4.html?utm_source=BP_recent" target="_blank">Part 4</a>.<br />
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<b>Wood</b><br />
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I wanted a bit of a retro look for my bike-rack, since I think it'll compliment the lugged frame well. That being said, I don't think that anything TOO retro will work. After all, it's a lugged frame with an 1 1/8" headset and compact geometry.<br />
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You can already see that the rack has a bit more "shaped" look than a lot of older racks. To offset that, I'm adding a wooden deck to the top.<br />
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<b>Frickin' Lasers</b><br />
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I'm no carpenter, and I've yet to take the woodshop safety course that would get me access to the tools I'd need here. I <i>have</i> taken the laser cutter course though, and can do pretty much everything I need with that. <br />
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Plus, you know... LASERS.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNH76hpoK2w7-ITAIxpBh3UTJrzzKypASjvZDL11mSmGjiPV7alnYPt8D4lusb2Abpv_b1rVTiRf3BtzndyJBTJ8LAKt9jdZxI9uo5N_qURlsvqKe-XLtwzsUth37BTNBRjdGIYPlYgLMd/s1600/IMG_20120413_225756.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNH76hpoK2w7-ITAIxpBh3UTJrzzKypASjvZDL11mSmGjiPV7alnYPt8D4lusb2Abpv_b1rVTiRf3BtzndyJBTJ8LAKt9jdZxI9uo5N_qURlsvqKe-XLtwzsUth37BTNBRjdGIYPlYgLMd/s320/IMG_20120413_225756.jpg" width="320" /></a></div>
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The laser cutter basically functions like a printer. The darker a color is, the more power the laser pumps out. You set it up for your materials, do some trial and error, and then burn the hell out of whatever you're etching. Specific line widths trigger a vector cut, which is usually set to cut all of the way through.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjb1skC5B9dk4Ix6HFOptNh2Yb_02NZhCRQT2OEKa4ZM1Gtpqo9IHEiD1yB9o6Hg1KMN0e2nc_p0pkwnbS4lGQeAe14XITJ5Se_a88NJvi0ssy_BfN4Mkzt-M3hXu-PRQU8oGsLOHOrQXGM/s1600/IMG_20120413_225845.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjb1skC5B9dk4Ix6HFOptNh2Yb_02NZhCRQT2OEKa4ZM1Gtpqo9IHEiD1yB9o6Hg1KMN0e2nc_p0pkwnbS4lGQeAe14XITJ5Se_a88NJvi0ssy_BfN4Mkzt-M3hXu-PRQU8oGsLOHOrQXGM/s320/IMG_20120413_225845.jpg" width="320" /></a></div>
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Since the cutter I was using could only go through thinner pieces of wood, I cut it out as two pieces: a top and a bottom. I also divided the file up into a bunch of layers, so that I could do all of the surface etching before cutting the piece away from the plywood sheet, which can shift things around a bit. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis5iO7n1KSkPaZWYCiUAZJu0WbL3r5oOERrOLynZLVZ_dY6C7th4yst3cNOJ_2Eso0SCR4YWVT2mHWAwnpOZLEfL9eI2e2p0_aAtZDuRmSLv5QQfJ5j-BRDVAaTs4CnXU-yzr8xWWwT0VW/s1600/IMG_20120413_225832.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis5iO7n1KSkPaZWYCiUAZJu0WbL3r5oOERrOLynZLVZ_dY6C7th4yst3cNOJ_2Eso0SCR4YWVT2mHWAwnpOZLEfL9eI2e2p0_aAtZDuRmSLv5QQfJ5j-BRDVAaTs4CnXU-yzr8xWWwT0VW/s320/IMG_20120413_225832.jpg" width="320" /></a></div>
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If you look carefully, you can see that I've cut my face into it next to the "if found, return to" bit in case I ever have to prove that I own the damned thing. The miracle of the laser cutter is that it's incredibly easy to do that kind of thing. </div>
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<b>Woodworking: An Inevitable Learning Experience</b></div>
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I had considered using the laser cutter to bore the screw holes in the deck for me, but decided to use the rack itself to line things up, since there were going to be some inevitable imperfections.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYfCVY5AKVt082K9L5097qHBMpe__GK9p1gJhMiEzin0KbOiersnaMRvejEqH5ryXQLJc9PCaibS6Cs1dUvfDvoXZAzesKS1qlqvKLKUHa-Anom3BTtt8k1bN-IxGGQ6DwDlGHK3GLwELL/s1600/IMG_20120415_135825.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYfCVY5AKVt082K9L5097qHBMpe__GK9p1gJhMiEzin0KbOiersnaMRvejEqH5ryXQLJc9PCaibS6Cs1dUvfDvoXZAzesKS1qlqvKLKUHa-Anom3BTtt8k1bN-IxGGQ6DwDlGHK3GLwELL/s320/IMG_20120415_135825.jpg" width="320" /></a></div>
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Once the holes were drilled in the bottom piece, I countersunk them a bit and then ground out a dimple on the top to make room for the head of the bolt. The idea is that the heads of the bolts are sandwiched between the two pieces, with the threaded ends sticking out. That way there are no holes in the top, but I can still secure the deck. I also cleaned the bolts with acetone in a glass bottle, to make sure that the glue would really stick to them. Don't be tempted to do this in the paper or plastic cup that you have sitting around your shop. It will melt and it'll smell <i>horrible. </i></div>
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I assembled the whole thing with a nice layer of heavy duty wood glue in the middle and tacked down the corners. Then, I clamped it in a vice with some scrap wood over it to prevent dents. If I were to do it again, I'd use much thicker wood scraps and drill it out so that the bolts wouldn't get in the way. As it was, I had to slip extra glue into a few areas using a business card and then re-clamp a couple of times.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxaesqzCTywsnOBvHehg_B5jZhqE86C7ktu6eDwG5JUCMvlgcGMCDa2_Nw15QOdEHxiKJeFQOhTKN7UjGMHU0zhyphenhyphenWklOcKrAfFlqSGzQrNcAsa9E5OHVMO6yq0TZCT7sDTd5BfgQugLbRc/s1600/IMG_20120415_173051.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxaesqzCTywsnOBvHehg_B5jZhqE86C7ktu6eDwG5JUCMvlgcGMCDa2_Nw15QOdEHxiKJeFQOhTKN7UjGMHU0zhyphenhyphenWklOcKrAfFlqSGzQrNcAsa9E5OHVMO6yq0TZCT7sDTd5BfgQugLbRc/s320/IMG_20120415_173051.jpg" width="320" /></a></div>
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<b>Finish</b></div>
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After a heroic sanding to round the edges and remove excess glue, I stained the deck (and some scraps) a bunch of times to find the right look. Lots of sanding and re-staining, and re-staining again with different stain on top... </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK_di5nTYAVsNQxKWA5aVy6cI5JJf8BziH19NANaStgq18r7pgjHVxYR095wqgADICXIniy4BzRrZf3Bw_ADbAswFzLZgEt_MGi1oDAX4PlHS_1cx6mENjr0L5_6olpQSVcNATXjKoDLu-/s1600/IMG_20120415_210416.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK_di5nTYAVsNQxKWA5aVy6cI5JJf8BziH19NANaStgq18r7pgjHVxYR095wqgADICXIniy4BzRrZf3Bw_ADbAswFzLZgEt_MGi1oDAX4PlHS_1cx6mENjr0L5_6olpQSVcNATXjKoDLu-/s320/IMG_20120415_210416.jpg" width="320" /></a></div>
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Eventually, I ended up coloring in the letters with a black pen for contrast, then staining with a light red and a dark brown stain. On top of that, I added three coats of a marine sealant designed for use on the railings of boats. It smells a lot like peppermint and probably kills you if you taste it out of curiosity.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTvlYwC17e9ahdr5FwuYj9OXN70GdevtERX6Op0yz0gXDayrRuAquOYzqiEmTO36n8Nee6kaE8c9k5zAdTkRswyeKItostl2lm3q00EzDPuNaI9R3MHPB0GW3jY5t53kGFMG3EliB0seOx/s1600/2012-04-28" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="377" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTvlYwC17e9ahdr5FwuYj9OXN70GdevtERX6Op0yz0gXDayrRuAquOYzqiEmTO36n8Nee6kaE8c9k5zAdTkRswyeKItostl2lm3q00EzDPuNaI9R3MHPB0GW3jY5t53kGFMG3EliB0seOx/s400/2012-04-28" width="400" /></a></div>
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I think it turned out pretty well. There are a few spots where I sanded too much near the edges. I think others will see them and think that they're intentional "weathering". They'll annoy me, but I'm going to wait until the bike is done to even think about re-doing anything on this.</div>
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<b>Next time:</b> hopefully I'll have some brazing (mostly practice) done for the next post. I planned on doing that today, but the tinted glasses that I'd been using for eye protection wandered off. I tried briefly to use darker shades designed for gas welding, and found that I couldn't tell the difference between a bit of red glow and bright screaming orange. </div>
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In this series: <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-1.html">Part 1</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-2.html">Part 2</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-3.html">Part 3</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-4.html?utm_source=BP_recent" target="_blank">Part 4</a>.
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<br /></div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-36775939281016839102012-04-22T18:09:00.001-07:002012-04-28T18:06:24.938-07:00Cargo Rack, Part 3<div class="" style="clear: both; text-align: center;">
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In this series: <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-1.html">Part 1</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-2.html">Part 2</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-3.html">Part 3</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-4.html?utm_source=BP_recent" target="_blank">Part 4</a>.<br />
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<b>Fillets!</b></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieJwzHFEXUsojm6DTyKpOrptPiVDeIj7L3W4y3cRP8XHhNFM_fst7GsmwR90YFsdtdYTkaHGty9ecGhVfEJ-64SJe1Z9YpsmdXI-CqFN8xMp8XR-WvehG23AdX5z64xG_kt5tfQc3ncVzs/s1600/IMG_20120418_215427.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieJwzHFEXUsojm6DTyKpOrptPiVDeIj7L3W4y3cRP8XHhNFM_fst7GsmwR90YFsdtdYTkaHGty9ecGhVfEJ-64SJe1Z9YpsmdXI-CqFN8xMp8XR-WvehG23AdX5z64xG_kt5tfQc3ncVzs/s320/IMG_20120418_215427.jpg" width="320" /></a></div>
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I finally got around to doing the fillets on the rack. I like doing fillets. You can see what you're doing a lot more easily than you can when you're trying to flow bronze under a lug. Something about there not being a sheet of metal between you and what you're working on.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitjf7olyAGGL6CMSGe7uT45BkcecILk15PdJb9edL8OSvD1BR_syiIblQd75kA0OY9UAoHFUuJ-kK8EmSeBVCpPw3iCfOwJYeAy1j4WLfComU5rOyyzX2sqtQsuItgwXiOtfCWb5JU365E/s1600/IMG_20120422_174352.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitjf7olyAGGL6CMSGe7uT45BkcecILk15PdJb9edL8OSvD1BR_syiIblQd75kA0OY9UAoHFUuJ-kK8EmSeBVCpPw3iCfOwJYeAy1j4WLfComU5rOyyzX2sqtQsuItgwXiOtfCWb5JU365E/s400/IMG_20120422_174352.jpg" width="300" /></a></div>
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Here's one that I started to clean up. You can see that the fillet forms a nice smooth transition between the tubes. There were a few spots where I didn't build up quite enough filler for that, but they're inconspicuous. Considering how thick I made the fillets overall, I'm not worried about it being structurally unsound. </div>
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If I'm feeling especially neurotic I'll fill the little gaps in with J.B. Weld. Since that particular epoxy has a bunch of powdered metal in it, the powder coat will stick to it.</div>
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<b>Sneak Peak</b></div>
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In our next episode, I'll get into how I'm making the wooden deck for this rack. It's all lasers and power tools!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUq2TF45bI_0R_IZ5vSYLlIp83x-DyBAbZ1ey_keiBHr2FE48Pn8YPTrkLcjBElMLGi-nBKFJMfFuudsrT8BIc_aTuc6zgPuAJcI5vpR25tW3AJ4iSt_JZ8FHCaAozIVrWaEi53vETbTUJ/s1600/IMG_20120422_172200.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="235" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUq2TF45bI_0R_IZ5vSYLlIp83x-DyBAbZ1ey_keiBHr2FE48Pn8YPTrkLcjBElMLGi-nBKFJMfFuudsrT8BIc_aTuc6zgPuAJcI5vpR25tW3AJ4iSt_JZ8FHCaAozIVrWaEi53vETbTUJ/s320/IMG_20120422_172200.jpg" width="320" /></a></div>
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</div>
In this series: <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-1.html">Part 1</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-2.html">Part 2</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-3.html">Part 3</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-4.html?utm_source=BP_recent" target="_blank">Part 4</a>.<br />
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<br /></div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-43937181384140744642012-04-09T00:20:00.000-07:002012-04-28T18:06:44.570-07:00Cargo Rack, Part 2<div class="separator" style="clear: both; text-align: -webkit-auto;">
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In this series: <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-1.html">Part 1</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-2.html">Part 2</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-3.html">Part 3</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-4.html?utm_source=BP_recent" target="_blank">Part 4</a>.<br />
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Yesterday I started brazing the rack, which was pretty exciting. In this step, I just laid down a bit of bronze to hold things in place. Later, I'll build up fillets. A fillet is a meniscus of metal that joins pieces together. When done properly, the metal creates a nice smooth transition between the two. </div>
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<b>Tabs</b></div>
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I cut the tabs out of some sample sheets of chromoly steel that I had lying around. They're basically little metal guitar picks. When the bike is done and all of the attachment points are installed, I'll drill them. That'll let me level it out if something weird happens. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvpnt530mhllYu7jaxiz6rqnlI2fwUqbNEBPhPD3ikmea5iwq5_0CrxVXpOa4Tkk1GfxZAnmOX47F-4JDQNGMxaxWc5_rwptSM2Mlk_Lz43Bt-m_nOUSsFmsdTNIOVslZBP9_GVvAah8x8/s1600/IMG_20120407_185130.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvpnt530mhllYu7jaxiz6rqnlI2fwUqbNEBPhPD3ikmea5iwq5_0CrxVXpOa4Tkk1GfxZAnmOX47F-4JDQNGMxaxWc5_rwptSM2Mlk_Lz43Bt-m_nOUSsFmsdTNIOVslZBP9_GVvAah8x8/s320/IMG_20120407_185130.jpg" width="240" /></a></div>
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I'm pretty sure, but not positive, that the sheets will be thick enough to resist bending when I'm carrying things. If I was using it for loaded touring, I'd double them up. I still may add a bit of reinforcement. </div>
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Once the tabs were done, I slotted the vertical tubes of the rack, lined them up with the tabs on my basic sketch, and then squeezed them with a pair of pliers just enough to keep them from shifting (much). </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1L3jJnD1woGNOK2sBUL04RlZWi6mEJ2Ml5CTEjaII5Kyd2E8CNCcMetSRv0eorZ3jUVuX-CvtXFfryml-DpuPNYETOk3XIZgvNoXE8c-DqHAeXmLapknleUnDmEXINNwn1kIPe0dzrsSd/s1600/IMG_20120407_185124.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1L3jJnD1woGNOK2sBUL04RlZWi6mEJ2Ml5CTEjaII5Kyd2E8CNCcMetSRv0eorZ3jUVuX-CvtXFfryml-DpuPNYETOk3XIZgvNoXE8c-DqHAeXmLapknleUnDmEXINNwn1kIPe0dzrsSd/s320/IMG_20120407_185124.jpg" width="240" /></a></div>
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<b>Brazing</b></div>
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I started brazing by securing the tabs. I did each of the four connections one at a time. The hard part was dealing with the last joint. It kept wanting to spring free, as the rack widens slightly near the rear (for aerodynamic effect, or something). I solved that with the sheet-metal vice grips that appear in one of the pictures below. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq2safq7TLzwcI_8VqL2K8bcK7urb2fMpQUXy_7736k-OhA-4uBLBzw-S2ELSBi7ScVe7NhK8FYryybXG5SHYsquW20_BSs6ugKT-udAGr7cX3P8qIbmYQeOTnQFc850GeJscKMPAdKuq-/s1600/IMG_20120407_200209.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq2safq7TLzwcI_8VqL2K8bcK7urb2fMpQUXy_7736k-OhA-4uBLBzw-S2ELSBi7ScVe7NhK8FYryybXG5SHYsquW20_BSs6ugKT-udAGr7cX3P8qIbmYQeOTnQFc850GeJscKMPAdKuq-/s320/IMG_20120407_200209.jpg" width="320" /></a></div>
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Next, I attached the rails, where a bag will hang. I clamped the first on one end, rotated it level, then tacked it on the other. Then I was able to remove the clamp and tack the remaining end. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbwb3AJrtwq0voxsmMffcFCX842UHUdZgKWtRlGw6wsywVbsUNCNni8VgQgBowIaQQEhJ_eg7L762nA55j0nPJ0oWXqSDwCiBq1MPewuESJz0qYfDswGFIZALlSETqLGYVg2Z5v6nPd1bd/s1600/IMG_20120407_211331.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbwb3AJrtwq0voxsmMffcFCX842UHUdZgKWtRlGw6wsywVbsUNCNni8VgQgBowIaQQEhJ_eg7L762nA55j0nPJ0oWXqSDwCiBq1MPewuESJz0qYfDswGFIZALlSETqLGYVg2Z5v6nPd1bd/s320/IMG_20120407_211331.jpg" width="320" /></a></div>
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The second rail was about 100 times harder, since it had to line up exactly with the first. At one point I probably would have hurled it across the room if there weren't other folks around working. Thankfully, after quite a bit of trial and error, it fell into place and I was able to tack it down before it slipped and hit me in the eye or something.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnDReCnT0IBL7rM2z3G3DWDD1ycchgqrZ_hXtXqKSeP5ENtd7D2f9nier7bWPzAPXqgk-0ueTZL8CW-dKVocXExB3BCnn-ht25i2s__vj34bdHeRQuAwkfYSjjkHSCznK0fw51n9dDxcG6/s1600/IMG_20120407_211428.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnDReCnT0IBL7rM2z3G3DWDD1ycchgqrZ_hXtXqKSeP5ENtd7D2f9nier7bWPzAPXqgk-0ueTZL8CW-dKVocXExB3BCnn-ht25i2s__vj34bdHeRQuAwkfYSjjkHSCznK0fw51n9dDxcG6/s320/IMG_20120407_211428.jpg" width="320" /></a></div>
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Here we go! I need to finish the fillets and grind the ends a bit, but the look and geometry work. </div>
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Next time: finishing fillets, adding tabs for the wooden deck, and making the strut to connect it to the seat cluster.</div>
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In this series: <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-1.html">Part 1</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-2.html">Part 2</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-3.html">Part 3</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-4.html?utm_source=BP_recent" target="_blank">Part 4</a>.<br />
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<br class="Apple-interchange-newline" />Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-20702600070495701192012-04-05T01:34:00.000-07:002012-04-28T18:07:13.885-07:00Cargo Rack, Part 1<div class="" style="clear: both;">
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In this series: <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-1.html">Part 1</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-2.html">Part 2</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-3.html">Part 3</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-4.html?utm_source=BP_recent" target="_blank">Part 4</a>.<br />
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I started making a cargo rack yesterday. My theory is that fillet brazing the rack will give me some much needed practice with my heat control. Additionally, a lot of builders at NAHBS used custom racks to highlight aspects of their frame, and I think I may have caught a bit of inspiration. </div>
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I'm using 5/16" diameter tubing, with .035" thick walls. I have some 1/4" tubing in the mail, which I'll use for the struts that run to the seat cluster, since it's a lower stress area. </div>
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I used a cheap, $10 tube bender. On the up side, it works. On the down side, the guide marks aren't really lined up with anything useful. I had to bend it little bit by little bit until it matched my blueprints. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtiIYqOyyq6mqS_9yZn5QETBfLId2ihCqB55xeJ1iFhTqiRqjxTSD53Ywexhm91_8xEfLs5wkVa0jjcOBkPe5v0sHa-A5tRVXt8ptSU2CIn2-C12z3KQ5koDgEvp4-RKVRGqLAAZ7BJh6T/s1600/IMG_20120404_233302.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtiIYqOyyq6mqS_9yZn5QETBfLId2ihCqB55xeJ1iFhTqiRqjxTSD53Ywexhm91_8xEfLs5wkVa0jjcOBkPe5v0sHa-A5tRVXt8ptSU2CIn2-C12z3KQ5koDgEvp4-RKVRGqLAAZ7BJh6T/s320/IMG_20120404_233302.jpg" width="320" /></a></div>
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The pieces already bent here will form the sides of the rack. They'll connect in front, and hang down a bit in back. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjec7j79svAhxe1RM_Z10obe70PqShk1ojHDna-k_eS8tF3ZkL9x7Gb5vfcNtqgplqjcmu543ul63-vh_Iv46ggq5heZWoItvX6wZ4sNgkmfR9b-lnWg_1tG3YaArb1W28IuNst6YYymPvI/s1600/IMG_20120405_005932.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjec7j79svAhxe1RM_Z10obe70PqShk1ojHDna-k_eS8tF3ZkL9x7Gb5vfcNtqgplqjcmu543ul63-vh_Iv46ggq5heZWoItvX6wZ4sNgkmfR9b-lnWg_1tG3YaArb1W28IuNst6YYymPvI/s320/IMG_20120405_005932.jpg" width="320" /></a></div>
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Here are the finished struts. Each U will cross over the wheel. </div>
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When I'm done I should have a light, narrow rack, slightly flared at the back. I'm planning to bolt a piece of finished wood to the top. Since I have a laser cutter handy, I'll probably engrave "Cedite E Campo", the motto of my fake bike company, into it in ridiculous flowery script. </div>
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In this series: <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-1.html">Part 1</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-2.html">Part 2</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-3.html">Part 3</a>, <a href="http://curmudgeonbicycles.blogspot.com/2012/04/cargo-rack-part-4.html?utm_source=BP_recent" target="_blank">Part 4</a>.<br />
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</div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-67655120705897383702012-04-01T23:34:00.000-07:002012-04-01T23:34:03.372-07:00Jigs and Silver<b>Jig</b><br />
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I put together my Half-A-Jig (tm) today. I'm using one piece of extruded aluminum from 80/20 and a couple of v-blocks designed for drilling tubes. One v-block is cut down to accommodate the lugs on the head tube, the points of which would otherwise keep the tube from lying flat.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9hIbncJeI5ahUbqFf0nzzTMV9kYJo89R_u3qP6we0jUpQn4U330Jg9oEnIHrOAf0d0YlKZ8oPmSpZkzssbJvC3-qb9eDNyNyHlbuilDVKEahrCEV5Xzxq_OeoCtt6RXDjKPMO7HymIpFk/s1600/IMG_20120331_164324.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9hIbncJeI5ahUbqFf0nzzTMV9kYJo89R_u3qP6we0jUpQn4U330Jg9oEnIHrOAf0d0YlKZ8oPmSpZkzssbJvC3-qb9eDNyNyHlbuilDVKEahrCEV5Xzxq_OeoCtt6RXDjKPMO7HymIpFk/s200/IMG_20120331_164324.jpg" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKPfRuYwi62WBe3g44hMUrNyQuZpuIBTH_vaKbJu4kpoCwX4Ag0k-zcjaC-ZBpXxU0BynGrXE_F-hRDZhMuYb-1R_wFY2O6ZsMAJSKUcGlNFXEcjONNkSn19HxWfo3VrcKV1lFoUO3pFci/s1600/IMG_20120401_171119.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKPfRuYwi62WBe3g44hMUrNyQuZpuIBTH_vaKbJu4kpoCwX4Ag0k-zcjaC-ZBpXxU0BynGrXE_F-hRDZhMuYb-1R_wFY2O6ZsMAJSKUcGlNFXEcjONNkSn19HxWfo3VrcKV1lFoUO3pFci/s200/IMG_20120401_171119.jpg" width="200" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_H-4B1hkHePzeJx53BRBHoFCwQRoUe3Mw1WZCDvSN8No8rAP-Ej2nddkGQXWsuOZcBYNhUssatwU_cr7nBhWNslDgj3Irz8DqFMhFUYPl0y7KC6VmAQFMLUaxuf7DsIrOSjkn7UkK_Wzv/s1600/IMG_20120331_171404.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_H-4B1hkHePzeJx53BRBHoFCwQRoUe3Mw1WZCDvSN8No8rAP-Ej2nddkGQXWsuOZcBYNhUssatwU_cr7nBhWNslDgj3Irz8DqFMhFUYPl0y7KC6VmAQFMLUaxuf7DsIrOSjkn7UkK_Wzv/s320/IMG_20120331_171404.jpg" width="320" /></a></div>
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The idea here is to help me align the head tube and seat tube so that they stay in plane, without spending $400 bucks and weeks on the materials to make a full jig. Basically, I wanted a bit flat metal bar, but I didn't want to deal with the issues involved in clamping a round tube to said bar. I had assumed that, in the process of getting it set up to work with the specific dimensions of my bike, I would have to shim things to get everything flat. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnhSwZhmp9dwg1Jlhp8JqOqAAp88hxgDoeMHKKLLd3FcMuHXyMlPDxxs-a9kjBATNFgP3Cs9IKTtXg4w2kszANN41aSb3ohEWok2pijwuJ_M64RRIASdAgIeV5Wh2GlOTJOx5S0M1JEK1M/s1600/IMG_20120401_171550.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnhSwZhmp9dwg1Jlhp8JqOqAAp88hxgDoeMHKKLLd3FcMuHXyMlPDxxs-a9kjBATNFgP3Cs9IKTtXg4w2kszANN41aSb3ohEWok2pijwuJ_M64RRIASdAgIeV5Wh2GlOTJOx5S0M1JEK1M/s200/IMG_20120401_171550.jpg" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiySq98U5Iy3MqVNcph84KFgunR4lUBTMHXvVpiT2eTtt6toKgfil7W0r0peFs7shodzxEGDPH_5Z3xlqf3effkSLIlDZti_2l6I-m6YgDsskt_ox6bo6KKQX5LlcvLTB30t9LAzp4484kz/s1600/IMG_20120401_171458.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiySq98U5Iy3MqVNcph84KFgunR4lUBTMHXvVpiT2eTtt6toKgfil7W0r0peFs7shodzxEGDPH_5Z3xlqf3effkSLIlDZti_2l6I-m6YgDsskt_ox6bo6KKQX5LlcvLTB30t9LAzp4484kz/s200/IMG_20120401_171458.jpg" width="200" /></a></div>
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I was pleasantly surprised to find that the two tubes ended up perfectly in plane! I had a bit of wavering, but it was between exactly level and .1 degrees off... I think I'll live. I may add some simple pipe clamps to hold things down so that I can tilt the whole structure to make tacking easier. </div>
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<b>First Silver Lug</b><br />
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I've decided to try my hand at doing lugs with silver. Silver melts at a lower temperature and has a bit more surface tension and a lower viscosity when melted. For these reasons, it can be a bit easier to work with than brass. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJL-igSq9OSOWb9edDbOqCkO1OIit2EPa2BYSWRIhAHFqiFVyq1hflA76ZukFR0GjctBz49mS5F7AnyQ_RkvKE-CEDh4Dq6ckYQeNIJp2XOIxPvqYundsapyL4khIUqH0mcNgO11bIFezb/s1600/IMG_20120401_181342.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJL-igSq9OSOWb9edDbOqCkO1OIit2EPa2BYSWRIhAHFqiFVyq1hflA76ZukFR0GjctBz49mS5F7AnyQ_RkvKE-CEDh4Dq6ckYQeNIJp2XOIxPvqYundsapyL4khIUqH0mcNgO11bIFezb/s320/IMG_20120401_181342.jpg" width="320" /></a></div>
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A practice joint mitered, lugged, fluxed, and ready to go!</div>
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<br class="Apple-interchange-newline" /><span style="text-align: center;">Results: I burned some flux. Having worked with brass mostly before, this isn't super-surprising. Temperatures that would be fine with brass are way outside of the range that I should have the metal while working with silver. I need to train myself to keep the flame back and moving more. If I can spread the heat out more instead of focusing so much, I should be able to draw things through better.</span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh67vA4z2XzQZXRR8h3QsZfDguv_0hgHR8YAFGuecBso1VHFT3KePBF-Ws9WpokAagnlZnaNbGlXCowFlh6MaaxJ23QZZOmvWETq3Kfy8HSITjFZjD9jeq7ZHwE5tUX4IUpf8QoLsYUBp8j/s1600/IMG_20120401_190215.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh67vA4z2XzQZXRR8h3QsZfDguv_0hgHR8YAFGuecBso1VHFT3KePBF-Ws9WpokAagnlZnaNbGlXCowFlh6MaaxJ23QZZOmvWETq3Kfy8HSITjFZjD9jeq7ZHwE5tUX4IUpf8QoLsYUBp8j/s320/IMG_20120401_190215.jpg" width="320" /></a></div>
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When I cut it open, I found that things were fairly well filled in most places, but still had some voids that I wouldn't want in a finished product. I'm going to do some more practice with random pieces of tubing and see if I can get past that point before I use the rest of my practice lugs. </div>
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<b><br /></b>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com1tag:blogger.com,1999:blog-8638154953594434939.post-4862811217753839322012-03-13T20:49:00.004-07:002012-03-13T20:49:48.369-07:00North American Handbuilt Bicycle ShowI had an AMAZING time at the show this year. I may have to fly out next year when it's a bit less local. Not only did I get to viddy some absolutely gorgeous bikes, but I also showed a few builders the head tube badge that I made with friends, and started investigating the prospect of selling them. <div>
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It sounds like we fall pretty squarely between the two methods that most are using. We can't compete with laser cut badges on price (they tend to be less than $5 each), but we'd most likely be a lot cheaper than the fancy cast-silver badges that are over $100. If we can really streamline the process, I think we can make it work, and allow more customizability than is currently out there. We're also looking at doing small runs of simple jewelry along the same lines. </div>
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If anyone out there has a design or idea they'd like to try, let me know, I want to troubleshoot an idea for an order process, and see how quickly we can do small lots. We'll give you a "early adopter" discount. </div>
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<b>Here are some bike shots, with minimal commentary:</b></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiy6itdGejYlIDt0iDXYb6xiHtXF7H2Pgxd3qAjody7o7_3hgxb0PtCaPKWXy8IBuT1ChMk5I2VE6_ILOR_3gawAD6v4kpJq1slMffFC6PluVs-DJFr4bTz0bJC6Ch0rgOj6c__2uSyed6s/s1600/IMG_20120304_145012.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="147" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiy6itdGejYlIDt0iDXYb6xiHtXF7H2Pgxd3qAjody7o7_3hgxb0PtCaPKWXy8IBuT1ChMk5I2VE6_ILOR_3gawAD6v4kpJq1slMffFC6PluVs-DJFr4bTz0bJC6Ch0rgOj6c__2uSyed6s/s200/IMG_20120304_145012.jpg" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCQ_6yBR9KkA8AGrF6JSn-vIVJQ-TjbTCTbqCEGST0597RWoLRm_Ekpg9AxQvCOZFwR04kiuHjHMmAD6HmARiIvKEWatRz1Bpq-SnJHMXirbvnwodbl__RkIewiZpGW0rkVQ0CXsSPDT55/s1600/IMG_20120304_144926.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="147" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCQ_6yBR9KkA8AGrF6JSn-vIVJQ-TjbTCTbqCEGST0597RWoLRm_Ekpg9AxQvCOZFwR04kiuHjHMmAD6HmARiIvKEWatRz1Bpq-SnJHMXirbvnwodbl__RkIewiZpGW0rkVQ0CXsSPDT55/s200/IMG_20120304_144926.jpg" width="200" /></a></div>
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A horror-bike by <a href="http://www.peacockgroove.com/" target="_blank">Peacock Grove</a>, inspired by the evil dead. Note the chainsaw blades on the chain. Hail to the king, baby.</div>
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Townies were all the rage this year. Heck even this road bike was a townie. It was made by <a href="http://www.lugoftheirish.com/Shamrock_Cycles/Home.html" target="_blank">Shamrock Cycles</a>. The water bottle bolts thread into beautiful little four leaf clovers. It's that kind of attention to detail that makes you wonder where those magic bike builders are hiding their pot of gold.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj3IT_RXaS3aZFssR6j3p4cplH_BCv-R7dGiItnHxe0omeTEbIxqryhrv65YRmGTgL9FBzUS2A4ITwZ4FfPCbn1-4fxJHhVaEnnarVf_sAQggmtQSJ4n1xlYtLJlmhMPIU0sHzD66C2U6P/s1600/IMG_20120303_151400.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="297" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj3IT_RXaS3aZFssR6j3p4cplH_BCv-R7dGiItnHxe0omeTEbIxqryhrv65YRmGTgL9FBzUS2A4ITwZ4FfPCbn1-4fxJHhVaEnnarVf_sAQggmtQSJ4n1xlYtLJlmhMPIU0sHzD66C2U6P/s400/IMG_20120303_151400.jpg" width="400" /></a></div>
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This was, without a doubt, my favorite thing at the show. The bike is amazing, but what really caught my eye was the trailer. The canvas was an awesome idea, and reminds me of a World War 2 era motorcycle side car. </div>
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Two details that you can't see in the photo:</div>
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1. The trailer hitch incorporates two Chris King headsets.</div>
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2. At the attachment point to the bicycle, there is a small lever that you can kick with your heel. This lever engages the disc brake on the trailer.</div>
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It was made by <a href="http://www.iraryancycles.com/" target="_blank">Ira Ryan</a>.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrMQ77lIx3Dc-Z4A9FvuEmJcntPpz52HrvYS1MVpNDw5Ge0MGroMReS9VFiVWRXX1O2-wob1GTq1UGH3gnr7OWjYjXEIxW9So_5yvMR5P-uUcD9ulSL6KX1P3JSQMu7Z4H3pUNSF_-YylQ/s1600/IMG_20120303_142506.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="148" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrMQ77lIx3Dc-Z4A9FvuEmJcntPpz52HrvYS1MVpNDw5Ge0MGroMReS9VFiVWRXX1O2-wob1GTq1UGH3gnr7OWjYjXEIxW9So_5yvMR5P-uUcD9ulSL6KX1P3JSQMu7Z4H3pUNSF_-YylQ/s200/IMG_20120303_142506.jpg" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhfuGAd3oRlc2wBqKRujoYHLUOLnVcapJnjQeymuRzMmtaE3RlaFaeR71Y7hKqjaJdwxwIq-9hZl3Uu0aDOLDeLM4f_qiJGTo-GDJQyvzKj5-6577cPf6eAwmrPKspvbEpc4BwvP7GgEaj/s1600/IMG_20120303_144703.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="148" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhfuGAd3oRlc2wBqKRujoYHLUOLnVcapJnjQeymuRzMmtaE3RlaFaeR71Y7hKqjaJdwxwIq-9hZl3Uu0aDOLDeLM4f_qiJGTo-GDJQyvzKj5-6577cPf6eAwmrPKspvbEpc4BwvP7GgEaj/s200/IMG_20120303_144703.jpg" width="200" /></a></div>
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This <a href="http://wheelfanatyk.blogspot.com/" target="_blank">Wheel Fanatyk</a> wheel is made of wood! Do not expose to fire or leave unattended near bike nerds, who may try to gnaw on it to absorb some of it's unearthly power.</div>
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The <a href="http://www.renovobikes.com/" target="_blank">Renovo</a> frame o<span style="font-family: inherit;">n the right is</span> also made of wood, and the same warnings apply. I'll trade you a kidney for one of these bikes. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcDOkJeLUqJS3AMF9PQKcNv_8QPY83UyUI48EIhoyopZkcgv5H6dIg_SDBSRt4a3WC91rf0g0_StpIawbZWpGMuFxJnZPtVkQJNYT6crM5k8jiSjMu5oq7ID9xCdzAaYPAxoIjGSY51j0t/s1600/IMG_20120304_162343.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcDOkJeLUqJS3AMF9PQKcNv_8QPY83UyUI48EIhoyopZkcgv5H6dIg_SDBSRt4a3WC91rf0g0_StpIawbZWpGMuFxJnZPtVkQJNYT6crM5k8jiSjMu5oq7ID9xCdzAaYPAxoIjGSY51j0t/s320/IMG_20120304_162343.jpg" width="320" /></a></div>
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<span style="font-family: inherit;">Awarded Best in Show. It's called Cherubim and was made by </span><span style="background-color: white; text-align: -webkit-left;"><span style="color: #202020; font-family: inherit;">Shin-Ichi Konno. The stem flows </span><span style="color: #202020;">seamlessly</span><span style="color: #202020;"><span style="font-family: inherit;"> into the frame. Beautiful is an understatement. If the alien from Alien wore </span>flannel<span style="font-family: inherit;"> and had an ironic mustache, he'd ride this bike around town. </span></span></span></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcmmSHdBSDZLD3gp7bNHBilcXek9R8W9piEJBbU39faFzB-aDh4R-pAYC0FlvJ-3wgKRSeZ_2fj283IVxJbLzAxvEJN0aCpIY5mT6ezXRRfxRuD5zvoChXmB2z0v2LZlG_nix3mksdFonT/s1600/IMG_20120303_164141.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="238" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcmmSHdBSDZLD3gp7bNHBilcXek9R8W9piEJBbU39faFzB-aDh4R-pAYC0FlvJ-3wgKRSeZ_2fj283IVxJbLzAxvEJN0aCpIY5mT6ezXRRfxRuD5zvoChXmB2z0v2LZlG_nix3mksdFonT/s320/IMG_20120303_164141.jpg" width="320" /></a></div>
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I'm finishing my seat stays in a similar way. Honestly, I can't remember who's frame this is. From the bike in the background, it could be <a href="http://www.rocklobstercycles.com/" target="_blank">Rock Lobster.</a> </div>
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<b>Jigs</b></div>
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After talking to a couple of builders about the subject, I've decided to simplify my jig plans. Instead of a bunch of struts, I'm just going to bolt two cradles to a bar of 80/20 aluminum extrusion and use that to keep the head tube and seat tube in the same plane. I'll handle the rest with careful measuring and by assembling the main triangle in stages. </div>
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That being said, check out this pro-level <a href="http://www.anvilbikes.com/soon.html" target="_blank">ANVIL jig</a>. It's designed to let you set up a build just by plugging the numbers in. It even has integrated grounds for tig welding. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5pXYZStFHyCquWAIl0WXH_RB9f8gaVeBv2wJVuGADg74_XLw6LYNaBcCPjKO5byPM5-S4RUUQ0vo4NmCXd4sCZ1Wg8hQLLAB7-fKC-57ejLrrym3JenQancwUiJoI8ka8f1sJlLj26RbY/s1600/IMG_20120303_142147.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="294" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5pXYZStFHyCquWAIl0WXH_RB9f8gaVeBv2wJVuGADg74_XLw6LYNaBcCPjKO5byPM5-S4RUUQ0vo4NmCXd4sCZ1Wg8hQLLAB7-fKC-57ejLrrym3JenQancwUiJoI8ka8f1sJlLj26RbY/s400/IMG_20120303_142147.jpg" width="400" /></a></div>
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<b>If you ever get the chance to go to one of these shows, DO IT!</b></div>
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<br /></div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-44635960257573300202012-02-27T00:49:00.000-08:002012-02-27T00:54:42.297-08:00Jigs and Rattlecad<b>It's Time For a Jig</b><br />
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I've decided to make a jig to hold the frame tubing while I tack things in place. It's possible to do the job without a more formal jig, but I think that I'm going to be better off with fewer things to think about while I'm putting everything together. I'll still have to get my skills pretty sharp to keep the frame straight, but at least this way I have a good solid place to start from. <br />
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I've decided to make the Jig out of 80/20 aluminum extrusions. Basically, 80/20 is a system of interlocking parts for building frames, jigs, supports, etc. They bill it as "the industrial erector set" and that's basically what it is. Here's an <a href="http://www.amazon.com/80-20-40-4012-T-SLOTTED-EXTRUSION/dp/B001F0G74M/ref=sr_1_6?s=industrial&ie=UTF8&qid=1330330808&sr=1-6" target="_blank">example</a> of one of the extrusions.<br />
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This isn't too much of a shot in the dark. Many builders have made their own 80/20 jigs, and a few pro's have even made production ready jigs out of it. Mine won't stack up next to an <a href="http://www.anvilbikes.com/soon.html" target="_blank">Anvil</a>, but if I'm careful about aligning everything, it should be good enough for me. <br />
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I'm basing my design on Suzy's over at Little Fish. She's been cool enough to put up a plan <a href="http://suzyj.blogspot.com/2011/10/basic-8020-spine-jig.html" target="_blank">here</a>. I'm going to use similar extrusions, but I'm going to move the vertical braces to the front of the jig. That will make it a bit harder to line up, but it should also allow me to work with a shorter head tube. As it stands, it looks like you need a really long head tube in that jig to clear the central spine, and then cut it down later. This will also mean that I'll have to remove the dog leg that centers the axle. It won't be as precise, but I think it'll serve.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRzca_Bq0HelS4LK6F9nqHe4CNBB4gwrqBjk7nx8YH2EezAktv6067A-zbZC7Gy3BKKyhvt4DnfKfPvmNRQMdHElJYMQVHIrhxc9JNOIihA-YKl4WyoUzpd3useXBqk-k9OUcMufxtLS0_/s1600/IMG_20120226_233902.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="235" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRzca_Bq0HelS4LK6F9nqHe4CNBB4gwrqBjk7nx8YH2EezAktv6067A-zbZC7Gy3BKKyhvt4DnfKfPvmNRQMdHElJYMQVHIrhxc9JNOIihA-YKl4WyoUzpd3useXBqk-k9OUcMufxtLS0_/s320/IMG_20120226_233902.jpg" width="320" /></a></div>
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<b>Rattlecad!</b><br />
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I discovered a discrepancy today in the spec's for the fork I'm going to use with my frame. It's a <a href="http://surlybikes.com/parts/pacer_fork" target="_blank">Surly Pacer fork</a> and I've found the distance between the dropouts (where it holds the wheel) and the crown (where it fits into the bearings of the headset) listed as 371 in one place and 376 in another. Yikes!<br />
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I've mentioned before that I'm using <a href="http://rattlecad.sourceforge.net/" target="_blank">RattleCAD</a> to make my plans and diagrams, instead of normal CAD software or BikeCAD (which you really need to pay for to get all of the information that Rattlecad gives you). It seems to be the best option for new builders, but it's also being constantly updated (at least 3 in the last month, maybe more). So, while adjusting the diagram to find out what the changes would have to be if that second number was the right one, I noticed that I could no longer manually change the virtual length of the top tube. That's the length that it would be if it didn't slant down a bit. For non-bike people following: this is a really important number because it has a lot of impact on where your handlebars end up.<br />
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I made a post in the RattleCAD forum about it and had an answer from the person making the software in less than a day. And it worked flawlessly. That's service, and on free software to boot! So yeah, if you're looking for a way to design your first bike or two, give it a try.<br />
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<b>Full disclosure: I don't work for Rattlecad dude, nor do I sell 80/20 as a side gig... I just think they're neat.</b>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com1tag:blogger.com,1999:blog-8638154953594434939.post-31306281718988900552012-02-19T22:03:00.000-08:002012-02-22T01:25:24.891-08:00We Need Those Stinkin' Badges, Part 2 (+ some brazing)<b>Bending the Badge</b> <br />
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If you haven't read it yet, here's <a href="http://curmudgeonbicycles.blogspot.com/2012/02/we-need-those-stinkin-badges-part-1.html" target="_blank">We Need Those Stinkin' Badges, Part 1</a>. <br />
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I made one more badge at a slightly smaller size a few days ago. Today I decided to get it finished and ready to attach to the bike. I started by trimming the excess off carefully with the band saw and this giant sanding disk. Then I lightly sanded the raised bits with a fine grit sand paper. That really set off a nice contrast between the higher and lower sections.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCd93ws4cSW-mZglT41aKdPb0-qM1zhUwy-RGozKGaNu2P9SVeQSXIfhRriFDpbvahPQ_7XwAnezH-30A5v2aeUgW3kRw3vp457i8xBZpx82Fu7tcYy1hhajFV0E6OuDebMX8siGfR3Pre/s1600/IMG_20120219_152641.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCd93ws4cSW-mZglT41aKdPb0-qM1zhUwy-RGozKGaNu2P9SVeQSXIfhRriFDpbvahPQ_7XwAnezH-30A5v2aeUgW3kRw3vp457i8xBZpx82Fu7tcYy1hhajFV0E6OuDebMX8siGfR3Pre/s320/IMG_20120219_152641.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZftf_k8cSiQFP3FT0RyJuO19G4DNKZwAhaLKenGSAepNO9IWV16apKWlSh8tP_Aq6NM8CDMoJQJD4WEtgfsNoxoIdeKlq0tZjv0H8e0Fjc78ROGT0KQdN2s8CP0lToTgOu7hHnCkh9-q8/s1600/IMG_20120219_152749.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZftf_k8cSiQFP3FT0RyJuO19G4DNKZwAhaLKenGSAepNO9IWV16apKWlSh8tP_Aq6NM8CDMoJQJD4WEtgfsNoxoIdeKlq0tZjv0H8e0Fjc78ROGT0KQdN2s8CP0lToTgOu7hHnCkh9-q8/s320/IMG_20120219_152749.jpg" width="320" /></a></div>
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The next step was to curve the metal to fit the front of the head tube. One of the guys at <a href="http://techshop.ws/" target="_blank">Techshop</a> was nice enough to cut a half-cylinder out of a piece of wood for me with the same radius as the tube (I haven't gotten checked out on the wood shop machines yet). I initially tried hammering the plate directly into the wood form with a mallet... but I couldn't get the angles right with the mallet I had. For my second attempt, I sandwiched the sheet between the form and a scrap piece of head tube and then squeezed them all in a vice. It worked... and also cracked the form down the middle.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ21S2ZnYiN7qCo9Gd2dMJ1IqXJRLR36EIggZ_Onqxvv_cSzXhZv9mVupbgcl_5oT_zvdWilW0CxwUxJeI3kqAaRb0GHAPXVJ2RHfXaQ8ox0NBItsTPUDXghsvSHFPeWsAYEWdn4TRcb57/s1600/IMG_20120219_152651.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIURxeMImanTrimoOtPj31nklYwM7C-Jgom1D9Kufk9gt3ctrBDafnxHr8mEOrklp0EVRC9HtZdzrFQkiCvKkei-4ffhVpPf0fzlJ4M0p-RXDBB1lGXzD3neO5U0FAUsYW6_YsWmgSi1tr/s1600/IMG_20120219_152831.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIURxeMImanTrimoOtPj31nklYwM7C-Jgom1D9Kufk9gt3ctrBDafnxHr8mEOrklp0EVRC9HtZdzrFQkiCvKkei-4ffhVpPf0fzlJ4M0p-RXDBB1lGXzD3neO5U0FAUsYW6_YsWmgSi1tr/s320/IMG_20120219_152831.jpg" width="320" /> </a></div>
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For the final piece, I held the form together from side to side with a clamp, and then used a combination of the mallet, a second clamp, and the vice to get everything straight and squished together. I used a sheet of paper towel to help the metal slide over the wood without leaving little scrapes near the edges as it was pressed inwards.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxrhIrB3VXfXA_QMebOudciupt_XdD1Mqjm7HrHf8FS1CSZWnjjMfupvlb7Rf8QksH3zIyF86Db6ojLrv0LCGgadMqVc43x67d9oTEI_drLGImJrbYJAl307iXwzX5_fvN6QqGMOgo5R3V/s1600/IMG_20120219_152808.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxrhIrB3VXfXA_QMebOudciupt_XdD1Mqjm7HrHf8FS1CSZWnjjMfupvlb7Rf8QksH3zIyF86Db6ojLrv0LCGgadMqVc43x67d9oTEI_drLGImJrbYJAl307iXwzX5_fvN6QqGMOgo5R3V/s320/IMG_20120219_152808.jpg" width="320" /> </a></div>
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When released from the form, the plate sprang back a bit, making the sides pull away from the tube. Some work with the mallet, first squishing the whole thing a bit, then spreading it back open over the tube, solved that. Because the mallet was plastic, and much softer than the metal, it didn't mess with the etch.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5edHnZOc3j0zmTQtSieDsWDIgLHkmsK5WGWHjyQS8OGKUKcq7KSMyvDw4cDWXclwINhyphenhyphenJ0zV2g-K0TxTzGp_U05qkw4d6J5zXdDKplSW-JTe6MMArxLsFbVVUTaJmXNU2-hRdCdwnuqQn/s1600/IMG_20120219_163357.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5edHnZOc3j0zmTQtSieDsWDIgLHkmsK5WGWHjyQS8OGKUKcq7KSMyvDw4cDWXclwINhyphenhyphenJ0zV2g-K0TxTzGp_U05qkw4d6J5zXdDKplSW-JTe6MMArxLsFbVVUTaJmXNU2-hRdCdwnuqQn/s320/IMG_20120219_163357.jpg" width="320" /></a></div>
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I encased the badge in a layer of rubber that someone happened to be messing with, to prevent corosion until I could clear-coat it... and then immediately found out that there was clearcoat up for grabs. So, I cut it out and used that.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEi1_lyiRt-KxRQjwh2NTcsWog5AOGRw3ZsDLiW3K-lND4xvbt6Au7vOFw0GUkhmGKJt85Rp8heppJzNdudw6tFLGqLIZKVwQR5S0C2xUxnhhN-_0o7VTCutnyplsSjQfIGLqE8Pys1UxX/s1600/IMG_20120219_215651.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEi1_lyiRt-KxRQjwh2NTcsWog5AOGRw3ZsDLiW3K-lND4xvbt6Au7vOFw0GUkhmGKJt85Rp8heppJzNdudw6tFLGqLIZKVwQR5S0C2xUxnhhN-_0o7VTCutnyplsSjQfIGLqE8Pys1UxX/s320/IMG_20120219_215651.jpg" width="320" /></a></div>
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Here it is finished! </div>
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<b>More Brazing </b><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrGXjy0efEeov2n5rLqxWpjJE6tgPAXYfUAOubjCBhYtihonR5g09iQ3-gQBZwPjUAXuxi3RkDtoXQx3HJfSxJaiS8Zv2-a7v4cMjFJhTnujmPTh7BjAARakfny5MsKrENOE4hj6azf2Ky/s1600/IMG_20120219_195559.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrGXjy0efEeov2n5rLqxWpjJE6tgPAXYfUAOubjCBhYtihonR5g09iQ3-gQBZwPjUAXuxi3RkDtoXQx3HJfSxJaiS8Zv2-a7v4cMjFJhTnujmPTh7BjAARakfny5MsKrENOE4hj6azf2Ky/s320/IMG_20120219_195559.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjly64fSkBmB6O28XO4pedJBjh2SNy_uBmybJxlxzbNAquAhEy8R-ymopt_sIeeRR4Iv-6Q3_Hq0NgKtwDmGzWL1L5KVegFD3segVdQCOGwdZDqnQhmrPYz3plw_Pfv3UgtVT6YZL2G_iT3/s1600/IMG_20120219_201624.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjly64fSkBmB6O28XO4pedJBjh2SNy_uBmybJxlxzbNAquAhEy8R-ymopt_sIeeRR4Iv-6Q3_Hq0NgKtwDmGzWL1L5KVegFD3segVdQCOGwdZDqnQhmrPYz3plw_Pfv3UgtVT6YZL2G_iT3/s320/IMG_20120219_201624.jpg" width="320" /></a><br />
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I also did a test-braze today. It turned out messy. As usual, I had issues flowing filler over the top of the lug, but I got most of it underneath. When I cut the joint open, it looked like it was pretty well filled with one small gap. I think it could have been used on a frame without much danger, which is reassuring.Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com3tag:blogger.com,1999:blog-8638154953594434939.post-11280183768203478542012-02-12T23:26:00.000-08:002012-02-12T23:28:00.287-08:00Seat Stays, Practice 1<div class="separator" style="clear: both; text-align: left;">
Today I worked on a potential finish for my seat cluster. The seat cluster is where the seat stays join the top tube and the seat tube. There's more variation in how builders construct this joint than in almost anything else on the bicycle, and many builders make the seat cluster their signature.. </div>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUTzqej5UQeWyWcvvRJ_nGdlH7eNBjaiC49iRkWnekgCF3RaxbMCsuGFJ06c4RCfAJeclUeOdQCA_ZZTV6Sx92gOCzZU2m4pWuL0strF0GDDiegNR6b44z-u9hXTGnIaCcvT3MtWnHUhxO/s1600/image" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="235" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUTzqej5UQeWyWcvvRJ_nGdlH7eNBjaiC49iRkWnekgCF3RaxbMCsuGFJ06c4RCfAJeclUeOdQCA_ZZTV6Sx92gOCzZU2m4pWuL0strF0GDDiegNR6b44z-u9hXTGnIaCcvT3MtWnHUhxO/s320/image" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Seat Stay Diagram: The Movie</td></tr>
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While I'm not up to the challenge of doing anything truly unique yet, I decided to try something that I've seen on a few of the prettier custom bikes that have come though my work.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj9NXnXR1ElznWmyvLDUXzjyhDvclaElrXgrSNLbmcvcTj51e6HRZCCg9KxEYTdSDyh7sLFCd9NBpM46XSbXnGlDHRqiIzn7MXIStkF3dBPrJP-oeAhRpXvwWiia_7-ahDrMt4sAGODjX_/s1600/IMG_20120212_183231.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj9NXnXR1ElznWmyvLDUXzjyhDvclaElrXgrSNLbmcvcTj51e6HRZCCg9KxEYTdSDyh7sLFCd9NBpM46XSbXnGlDHRqiIzn7MXIStkF3dBPrJP-oeAhRpXvwWiia_7-ahDrMt4sAGODjX_/s320/IMG_20120212_183231.jpg" width="320" /></a></div>
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First I mitered the stay so that it would fit up against the side of a 31.8 mm tube.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8_nQAEBIvl6BB8ko_BNvSZFZ4uxp3gHyXaCJVJM-u0_IeRip19tXuZ7QGlgNVd2FzMSPClIBMCYWzRXB81tYYFbYIe5aue7rrzlgHqM46l1Hl_RfHoHBA32L1XtplORerQwfDu6Y3h1GT/s1600/IMG_20120212_183338.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8_nQAEBIvl6BB8ko_BNvSZFZ4uxp3gHyXaCJVJM-u0_IeRip19tXuZ7QGlgNVd2FzMSPClIBMCYWzRXB81tYYFbYIe5aue7rrzlgHqM46l1Hl_RfHoHBA32L1XtplORerQwfDu6Y3h1GT/s320/IMG_20120212_183338.jpg" width="240" /></a></div>
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Then I cut a piece of said tube, and brazed it onto the stay.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwFg19GSSde-DzIDCdovHsF3M-EUreRBPdisyrB9_MBFzVVxSuDPxJFSDy9SG2fm1ukgkU39DUoqtja-h0ZYplXtpo93o8oYLCaUiTE4WwsfXDBfPN62hMZWyFn4ngCpS-D2AYtZavTkUQ/s1600/IMG_20120212_193150.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwFg19GSSde-DzIDCdovHsF3M-EUreRBPdisyrB9_MBFzVVxSuDPxJFSDy9SG2fm1ukgkU39DUoqtja-h0ZYplXtpo93o8oYLCaUiTE4WwsfXDBfPN62hMZWyFn4ngCpS-D2AYtZavTkUQ/s320/IMG_20120212_193150.jpg" width="240" /></a></div>
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I treated it like a fillet, where you build a smooth transition between one tube and the other. It was more brass than I really needed for this cap, but it was a fun experiment. I think that I could really enjoy fillet brazing. Something to think about when it comes to frame #2.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFlZhGfJ5dXdMlQtb02LUQLk_aNsMwt3O9Akw0jbJ_HZnt_rpAE_ofLRMguMb0l18awGLfmWz5-pQ3Zo5d9gHWUFFi4T6KiQ1NiSAL9AIZn1z7QVpWZZnxv19LCaPOdgHEt6f0NVMHmW29/s1600/IMG_20120212_195319.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFlZhGfJ5dXdMlQtb02LUQLk_aNsMwt3O9Akw0jbJ_HZnt_rpAE_ofLRMguMb0l18awGLfmWz5-pQ3Zo5d9gHWUFFi4T6KiQ1NiSAL9AIZn1z7QVpWZZnxv19LCaPOdgHEt6f0NVMHmW29/s320/IMG_20120212_195319.jpg" width="240" /></a></div>
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Here's the finished piece. It'd be attached to the side of the seat tube with the longer side in. I think that two of these will look pretty sweet on there.</div>
<span style="text-align: left;"><br /></span>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0tag:blogger.com,1999:blog-8638154953594434939.post-70701626602979800562012-02-07T11:23:00.000-08:002012-02-07T11:29:22.377-08:00We Need Those Stinkin' Badges, Part 1<b>Chemicals</b><br />
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I'm using ferrous chloride to etch my head tube badge out of copper or bronze. My initial tests have been with copper. <br />
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Ferrous chloride is pretty mild, as a far as stuff that can eat metal goes, but that's still a scale you have to respect overall. As long as you don't get it in your eyes or let it linger on your skin, it's not going to mess you up (use ventilation too). It will eat metal, obviously, including your sink. The copper ions it absorbs when you use it are also environmentally harmful. You have to save your waste and dispose of it properly (local hazardous waste disposal should have some idea how to handle it).<br />
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It won't eat through plastic, glass, or a few other random things. I made sure that all of the dishes and bottles that I used were plastic.<br />
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<b>Resist</b><br />
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I won't go through all of my trial and error, because there are a million sites up with different instructions for etching with ferrous chloride, for both art and making circuit boards. The short version is: we need to get something onto the metal that the etchant won't eat (a resist) in the shape of the image. Then we dip it, and everything else gets eaten down a few mm.
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWLoaN1IpUlh8vAa9r_L0nySLR5Qdrf2sihyAsM_1eImnxlJXo0oF6thOSOc9JMa-XeOZlW5oXbJtfywGAi7boITMXohDQfGws5iSmOP8xyyotl7ffgwN1_m8d-YOO3QVSpuR_H2RXR7dA/s1600/IMG_20120204_191044.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWLoaN1IpUlh8vAa9r_L0nySLR5Qdrf2sihyAsM_1eImnxlJXo0oF6thOSOc9JMa-XeOZlW5oXbJtfywGAi7boITMXohDQfGws5iSmOP8xyyotl7ffgwN1_m8d-YOO3QVSpuR_H2RXR7dA/s1600/IMG_20120204_191044.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWLoaN1IpUlh8vAa9r_L0nySLR5Qdrf2sihyAsM_1eImnxlJXo0oF6thOSOc9JMa-XeOZlW5oXbJtfywGAi7boITMXohDQfGws5iSmOP8xyyotl7ffgwN1_m8d-YOO3QVSpuR_H2RXR7dA/s200/IMG_20120204_191044.jpg" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhP4s1DKaDViy9gwQPyjY6AnLPyt3pIFZ-jhF9iigp9ZuzyABBCS5C77b83qkj7fQim_20_7FSt0XpmfMen_e6say9c8mK6Dy5vzziTvpAjf_o8tr3mj0_e7q2zXXJpiitmCvY6jRJSdVF/s1600/IMG_20120204_191054.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhP4s1DKaDViy9gwQPyjY6AnLPyt3pIFZ-jhF9iigp9ZuzyABBCS5C77b83qkj7fQim_20_7FSt0XpmfMen_e6say9c8mK6Dy5vzziTvpAjf_o8tr3mj0_e7q2zXXJpiitmCvY6jRJSdVF/s200/IMG_20120204_191054.jpg" width="200" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTaEOkC4qmUZJKvP0unjQ8RnnR1ZTsYDflRpGO9BYR6AuGLoh3uxI30TKwxBzt1MWjqjb4qnVfIIEHw5kWOXDSJmKhpPEW6Roa9WWQp8bI50ZgCgNqXjFCJbMClvdvaBiCzWw5dBRl-_qJ/s1600/IMG_20120204_191107.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTaEOkC4qmUZJKvP0unjQ8RnnR1ZTsYDflRpGO9BYR6AuGLoh3uxI30TKwxBzt1MWjqjb4qnVfIIEHw5kWOXDSJmKhpPEW6Roa9WWQp8bI50ZgCgNqXjFCJbMClvdvaBiCzWw5dBRl-_qJ/s320/IMG_20120204_191107.jpg" width="320" /></a></div>
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Eventually, I ended up printing the design (reversed and inverted) onto a page out of a National Geographic using a laser printer (toner makes a great resist, inkjet ink doesn't). Any shiny magazine paper should work as well, but National Geographic adds a bit of class. I ironed it in place, soaked it and sprayed it with water until most of the paper flaked off, leaving just a thin layer stuck to the toner. I found that the transfer worked best if I left the iron on the back of the plate for about five minutes to get the plate nice and toasty, then flipped it and heated the back of the image for another five. I touched up the finished product with a few dots of Sharpie marker, which is a passable resist, and then used a vertical band saw to trim the metal around the edges.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlByoO5-5lABc6S3qu74FA0vhyphenhyphenXDUgLKaUJh0bvgL8ogwPPGl7Ptwp_4r1siSrkX4pkKqcwWTm1GtiRIcg4f6JqXcNPtcMVFf8IXaJYTnRuq8HrGQ7j2YWfVPbN5mryM9r6BdPBE6eqcjd/s1600/IMG_20120204_191129.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlByoO5-5lABc6S3qu74FA0vhyphenhyphenXDUgLKaUJh0bvgL8ogwPPGl7Ptwp_4r1siSrkX4pkKqcwWTm1GtiRIcg4f6JqXcNPtcMVFf8IXaJYTnRuq8HrGQ7j2YWfVPbN5mryM9r6BdPBE6eqcjd/s200/IMG_20120204_191129.jpg" width="200" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEqOxL4v2Rdcg0_GGj78IDNbdK3ggJjNRYfXE4ijcqLuVjucztr6dhfTosvnPd1qjkkfSzoaGGZckFgyLKeWEj8uOiktrM3qyasParNBN8ZTLdPnJA4YqOliiOyrbw521zGUouo0LGrhyC/s1600/IMG_20120204_191535.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEqOxL4v2Rdcg0_GGj78IDNbdK3ggJjNRYfXE4ijcqLuVjucztr6dhfTosvnPd1qjkkfSzoaGGZckFgyLKeWEj8uOiktrM3qyasParNBN8ZTLdPnJA4YqOliiOyrbw521zGUouo0LGrhyC/s200/IMG_20120204_191535.jpg" width="200" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcVBcu4wUnhFxGb_-9fzsnplD4pWIVIWYG11-Z2NmjQW-0PKbXjoBNMbfQAMeCqrnxIjB0xpazcFEbm-hACIDToPR2LUwR1aixzvQX7f_frHPMqIKRtZkxBxenTZAD16YszLXV2-wIvGFA/s1600/IMG_20120204_192924.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="150" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcVBcu4wUnhFxGb_-9fzsnplD4pWIVIWYG11-Z2NmjQW-0PKbXjoBNMbfQAMeCqrnxIjB0xpazcFEbm-hACIDToPR2LUwR1aixzvQX7f_frHPMqIKRtZkxBxenTZAD16YszLXV2-wIvGFA/s200/IMG_20120204_192924.jpg" width="200" /></a></div>
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<b>Etch</b></div>
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I did a quick test piece first, which failed miserably. I was pretty bummed until I put together that the 40 degrees out on my porch probably wasn't an optimal temperature for this reaction. I suspended the plate upside down in a piece of Tupperware using tape, with ferrous chloride just covering it. Leaving it upside down keeps the waste products of the etch falling off of the plate so that they don't leave uneven bits.</div>
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Next, I moved the whole deal into my apartment (inside a trash bag, to prevent leakage and contain fumes), and left it in a shallow plastic dish of hot water for an hour and a half. </div>
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<b>Success!</b></div>
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When I removed the plate, I had this:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjA5K8rWJzSssz9dpBWLYcz-xaSoNfMN7z2HzVTv5fTAvrnW9Go721-iK578l7K1Rs8W0-MojnDeGhFaM48KBZg6b9_EBtRRblRpx6r-8ZXkknsyaEuiISO152y7YLnIWkcLeveC5jaVFTM/s1600/IMG_20120205_013547.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjA5K8rWJzSssz9dpBWLYcz-xaSoNfMN7z2HzVTv5fTAvrnW9Go721-iK578l7K1Rs8W0-MojnDeGhFaM48KBZg6b9_EBtRRblRpx6r-8ZXkknsyaEuiISO152y7YLnIWkcLeveC5jaVFTM/s320/IMG_20120205_013547.jpg" width="240" /></a></div>
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Good so far! To neutralize the residual etchant, I dipped it in a mixture of baking soda and water. Then I scrubbed it with acetone and, as a quick final touch, repeated the entire process with a slightly different design.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjsiZjyXn5OK7oGpHS-yPQvZ7ETmzu1jspgt4Pxc7PMy4IUFgs0BahBR99_PVI115C9GA2pBr5aOAK_AQoZ-dvANzAGVhwQpIWviFj9MyBtahM9oCAD_oJeKC3-QMND9eq0pg9G80glpS7/s1600/IMG_20120205_165427.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjsiZjyXn5OK7oGpHS-yPQvZ7ETmzu1jspgt4Pxc7PMy4IUFgs0BahBR99_PVI115C9GA2pBr5aOAK_AQoZ-dvANzAGVhwQpIWviFj9MyBtahM9oCAD_oJeKC3-QMND9eq0pg9G80glpS7/s400/IMG_20120205_165427.jpg" width="400" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvjR-FhJuNwYCDGmZDJMhS14mbwvpy17TM-RppAXICHd1D4TmSTvEkvvwChxTwkWqfZ5xUb-E2r82o_KMZtAzxHcdP142bL0kGasgVV0ztNaknpsvL9-3StF6B-1bTzW-xX79Vtrkq3ypQ/s1600/IMG_20120205_165524.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvjR-FhJuNwYCDGmZDJMhS14mbwvpy17TM-RppAXICHd1D4TmSTvEkvvwChxTwkWqfZ5xUb-E2r82o_KMZtAzxHcdP142bL0kGasgVV0ztNaknpsvL9-3StF6B-1bTzW-xX79Vtrkq3ypQ/s400/IMG_20120205_165524.jpg" width="400" /></a></div>
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Now I just have to hammer it until it'll curve around the head tube and then paint it. I plan to add some black paint to the lower sections and then clear coat it.</div>
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<br /></div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com2tag:blogger.com,1999:blog-8638154953594434939.post-52794317931689498282012-01-30T21:31:00.000-08:002012-02-07T13:38:07.802-08:00Ignore This Boring Post About ButtsOne quick bit of advice for anyone else embarking on this whole frame building thing. Always ALWAYS measure your tubing. Most of the tubes we use to make a custom bike are butted, meaning that they are thicker on the ends and thinner in the middle. This lets the thicker section soak up the higher stresses near the joint, while the thinner section makes the finished bike a lot lighter. <br />
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<tr><td class="tr-caption" style="text-align: center;">This instructive daguerreotype, found in my great grandfather's memoirs, should help to illustrate what's going on inside the tube. </td></tr>
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You have to be careful though, because you can cut too much off of one of the ends and end up with some of the thinner tubing forming the joint... which may then fold like a coke can. Even worse, tubing often comes with the butts shorter or longer than the spec sheets tell you they should be, so you really have to measure for yourself to be sure.</div>
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I held my tubes up to a bike light and stuck the depth measuring tool on a caliper into it, set for the point where the transition was SUPPOSED to start, then made sure that it lined up with the actual change in reflection indicating the start of the slope towards the thinner spot. It can be hard to see what's going on in those things, so I had to bracket the measurement (-10mm is DEFINITELY falling short, +10mm is DEFINITELY going over that line).</div>
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I found two discrepancies: my seat tube started getting thinner about 1.5 cm lower than it should have and my chainstays (which are ovalized) are about 2.5 mm too wide and a bit too short. The first won't be an issue provided that I leave the tube as long as possible when shaping the end to fit into the bottom bracket lug. The chainstays will probably need to get just a kiss from the vise to be the right shape. I'm a little nervous about that, but it shouldn't be a big deal.</div>
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Now I have everything marked, so I will know EXACTLY when I'm in trouble as I trim stuff to length and shape the ends. <b>Next post will likely be about some more practice welds, which will hopefully be more interesting than all of this measuring.</b></div>Anonymoushttp://www.blogger.com/profile/12744938692849246661noreply@blogger.com0