Monday, December 21, 2009

Nich's Fork

Nich found me through my Ebay store and order this lugged fork that I was selling as an add on to my fixie frame.

This will be a straight leg fork at 45 degree rake in the crown.



minutes after brazing.

After soaking in hot water and a little wire brushing to get a couple little black soot spots off.

Looking in the cavity of the crown you can see the nice fillet the silver makes around the sockets. This means this fork crown is now one single piece with the steerer tube, the two pieces of steel are complete bonded together.

After some quick filing and sanding clean up, cleaned up the little spots of silver left on the steerer.

About to braze the legs into the crown, the clamps are only holding the points of the crown sockets with light pressure. This is to make sure there are not gaps so the silver does not have to fill in or build up to bond the socket points onto the fork legs.


After soaking the crown and drop outs, I am sanding and filing every thing now.

Nice smooth steerer integration after a little filing, It looks like one piece now.

A little more sanding and it will be ready for paint...

I do all my own painting now so I though I will show a little of the process, this a direct to metal base coat. Its thick enough to sand and smooth for the next base coat layer...

Since the fork will be black, this is a black base coat. It makes the semi opaque black color seem very deep and rich with black.

One more coat of black base after this and it will be ready for the color...

After the final coat of black I did a silver highlight inside the sockets. It's hard to see here but I also added just a little metallic silver very lightly sprayed over the black to give it a little more depth and sparkle... it adds a cool effect you can see in the final pics.


This is the finished with clear coat fork, you can start to see how rich and deep the black is...



Look close and you can start to see the sparkle of the metallic silver over the black.
In the sun the metallic silver really makes it shine and adds depth.



Well all in all this was a fun little job, Nich really liked it and hopefully he gets to ride it soon if the new twins don't mind him taking a break from daddyhood.

2 comments:

Unknown said...

Mark,
Dude, where have you been? I look every once in a while to see if you are around and nothing. Then all of a sudden you have a fillet brazed bike up on your blog. Kudos on the nice job. What are you using for a jig. Stay in touch and keep posting.
Thanks, Wil

Mark said...

Well you know, got busy and never found time to blog. But I will try and keep up with it now.
Thanks and good luck with your projects.

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