Thursday, January 15, 2009

Braze-on time!

I did a few different things last night: brazed in the bottle bosses, brazed on the cable stop for the rear derailuer and pulled the right seatstay drop to straighten out the wheel in the rear triangle.


So my previous "New" method of brazing is working well. But you can see here I overheated the flux just a little but it still wiped right off with a wet rag.


This is after I had heated the seat stay/drop joint and pulled it. I ended up having to pull it about 2 mm to get the wheel straight at the brake bridge within 1mm of center. I ended up having to turn the frame over and try and get all the silver to go back down in the joint because it all came flowing out when I pulled on it.

The cable stop for the rear derailuer, I was kind of practicing a fillet (it is really hard with 56% silver) it came out pretty well.

This is the other set of bottle bosses on the DT after wiping off the flux, you can see I didn't over heat anything and I just got a little silver build up on one tip. These were a lot easier than I thought they would be.
I also bored the seat tube for a 27.2 post and cut the slit in the seat clamp, I didn't do that great of a job on that so I might key hole it to clean it up. I also taped and faced the BB with my new Ice toolz kit... man it is nice having my own set of tapping and facing tools.
I may not be able to do much on it for the next couple days but saturday I plan on cleaning everything up and possibly building it up for a ride! cross your fingers.

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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