Wednesday, November 12, 2008

I'm Mitering (moving right along) now!

So this is moving fast now, Last night I was able to clean up the bottom bracket to just leave a little sanding and mineral spirits cleaning for brazing. And I have to admit I was very nervous about mitering the down tube/head tube joint, I was very cautious in starting and it ended up taking me about an hour to miter this cut and get it to fit flush to the head tube.
I admit I really thought I screwed up when I did my 1st test fit because it was way off, with frustration starting I sat back and assessed the problem. Luckily for me my engineering aptitude (that everyone always says I have) kicked in and I realized that the "waist" or side peaks were way to high slightly misshapen. So I filed them down just a little to see if I was right... yup that was it.

Once I got a nice clean fit, I filed and checked, filed and checked, and filed and checked again. But I couldn't get that fit of absolutely no light shinning through? So I sat back and read a little bit and pondered how serious I need to be with this fit. So I decided to reshape it a little more and see what different filing will do, I fugured when I read so many builders blogs about making sure no light is shining through at these joints then I had better take this serious.
So another 15 minutes of filing I came up with this fit below. It could be better but I feel it falls into the criteria that Tim (Paterek) instructs in the manual and many other builders strive for in their blogs.

Once I was satisfied with the miter I nervously checked the fit between the head tube/down tube and the bottom bracket/down tube... it is so close to the drawing that once I braze these together the BB facing and cuting tool will just barely nick a piece of the tube when it is doing it's thing. You can see in the pictures below how clean the fits are.
Now I basically just have to cut the fork blades (straight legs with plug in drops) and prepare it for brazing as well as prep what Tim calls the subassembly with mineral spirits and some sanding.
Not sure if I will braze this week or hold it for friday night and saturday because I won't have much time tonight and tomorrow night because that is Hannah and me time.





I will be using pins to keep the frame aligned because I don't have much in the way of fixturing so for this frame I will clamp everything on V-blocks (seen in the picture above) and then pin the HT/DT for brazing and then pin the BB/ST for brazing to follow the Paterek build up.
If anyone has any suggestions on pining or clamping feel free to let me know...


1 comment:

David Popdan said...

one trick you could try is to wrap a piece of sandpaper around the headtube and use that as a tool to finish the miter on the down tube.

The lessons I am learning are amazing and really fun to work out...

The pictures below are the work I did last night, finished grinding the bottom bracket sockets.
Notched out the seat stays to fit the drop outs...
And the big big moment... doing my 1st miter on the seat tube (Tim calls this one the most forgiving miter and he is right)

I think that many of the lessons and techniques I have learned from wood working are carrying over into metal working very nicely.

bottom bracket, right side done (before finshing sanding)

bottom bracket, right side done (before finshing sanding)
the left socket is just starting to get ground, notice how thin the walls of the right socket have gotten. there is a lesson there and you will see in following pics!

grinding with a stone

grinding with a stone
it took a while with this stone but with the tight corners I had to use it because I only have one small sand paper bit left

ooh ahhh... a little sparks flyin

ooh ahhh... a little sparks flyin
That lesson I spoke of earlier is happening in this pic...

Ahhh... oh DOH!

Ahhh... oh DOH!
is that blueing? Yup that is the lesson that I learned on this socket. the grinding stone heats the metal very fast and as that wall gt thinner it started blueing. Bad, bad, bad! so I will have to sand and reshape that wall a little because I even got some chipping around the blue.

Chain stays with the drop outs notched in...

Chain stays with the drop outs notched in...
So this one was a little scary because I wasn't sure if I would get them straight and true... it ended up ok but I can do better.

Notching wasn't to hard but keeping everything even was hard

Notching wasn't to hard but keeping everything even was hard
I decided to try the bevel sides on the notch, I think I can do better so I may do the stays again?

The big moment... my first miter!

The big moment... my first miter!
I should have taken some before during and after shots but this went pretty fast actually. this is the ruff cut, I rounded it out better and got rid of that hump on the back wall

A little different angle... check out my home made tube holder... works like a charm!

A little different angle... check out my home made tube holder... works like a charm!
I am so proud of the wood block tube holder... now I just have to make the other sizes

A quick fit test...

A quick fit test...
Not bad forthe 1st miter and fit check... I only need to file the inside edges to match the bevel of the inside of the BB

Nother fit check after some finishing

Nother fit check after some finishing
still need to angle the inside of the edges then it is done and ready for finihsing before brazing. I also still need to finish the socket wall to clean up any uneven edges or tooling marks