Monday, January 26, 2009

Built up and ridden 50 miles...

Well here it is, I am very proud of my 1st build. It rides super smooth and stiff (like I like it) I will need to get a Surly tug nut so the wheel won't slip and because I don't want to tighten the rear skewer so much that I can't open it out on the road.
I am taking it in for powder coat today and should have it back next week.





1 x 10 gears work great... it's a 50 tooth chain ring. I will report later on how it does for longer hilly rides. I centered the ring by mounting it on the inside of the spider so I can go through all 10 gears with very little chain alignment stress at the 25t

Not a real clear photo but it looks pretty good for a 1st timer.



I decided to build a new fork over the weekend and didn't take the time to shoot pictures during the process. But here are a couple close ups of the finished fork; I really like these Ritchey crowns from www.bikelugs.com they are cheap and pretty light weight. It's an internal plug style crown (to match the drop outs) I had a hard time figuring out how to do the brazing but after a few issues with one drop out I worked out all the kinks.
Basically I drilled vent holes on top and bottom of the legs then a feed holes just at the top of where the plugs are inside the leg. That helped make sure my silver was going all the way up and around the plugs, I even fed enough silver for the drill hole to fill in on itself (not the vent holes though).
The crown was much easier because it is easier to control the heat and take my time, I fed a lot of silver in there so I am more than positive there is a nice fillet inside. The nice thing about this style crown and drop is it takes all of about 20 minutes to clean and finish the brazing joins.

The only issue I really had was bending the legs to match each other, these were the 1st set I bent and they look OK but there is a very small lump (almost like a kink) on one leg. The issue was keeping them from twisting while bending each one... I had a pair that twisted inward and looked horrible when mounted so I scraped them. Also it is hard to get the radius I wanted and to match both legs but I got pretty close after scraping the second set and I am confident the next fork (which I will probably start on this week) will be much better.




I am very proud of the brake bridge, it looks great.


The seat stay tops are OK after lots and filing and shaping but I think I will be a lot more careful on the next build to align them right and make sure the fillets match.


Since the bottom bracket was one of the 1st things I brazed, it leaves a lot to be desired. But the good thing is by the time I got to the chain stays I was pretty comfortable with brazing, and they look much better than the ST and DT.


I am pretty satisfied with the rear dropouts but I will do them a little different on the next one to keep them looking uniform and cleaner.

The internal cable runs came out pretty clean, but there is lots of room for improvement. I will also need to adjust my placements because this one just slightly touches my leg while peddling.
But I still really dig the look and style of internals so I will focus on getting better at placement and brazing them.

The cable routing is just a little funky around the head tube so I will confront that on the next build but it doesn't affect performance and I have seen mutch worse on some higher end frames.

5 comments:

Unknown said...

Good job Mark! I feel your pain in having to toss tubes away. I'm not sure I understand what you are saying in regards to brazing the crown, but it looks good. Show more pics if you get a chance. I feel the same way about drop-outs and skewers. I found some old Dura-Ace steel ones that really hold. I'm not sure the new ones are made for slotted drop-outs. Anyway, looking forward to your next build.
Craig

Unknown said...

way to go Mark. I am glad to see that it rolls. I noticed your comments about the fork plugs. You are supposed to put a ring of rod inside and let gravity pull it into the joint when you heat it with the torch. It is quite amazing how it works. Look in the Paterek manual. Keep it up. Can't wait to see it with color. Wil

Unknown said...

is it off to get color?

Mark said...

Yeah I just got it back so I will post some pictures of it fully built later this week.

Unknown said...

come on Mark. Give it up. I am waiting to see the pictures.

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