Friday, May 28, 2010

Debi's Fork

Well this was a pretty simple uni-crown fork that Debi asked me to make for her. I used stainless drop out inserts for a polished finish at the drops.
Below is before and after of the drops after removing the rack tabs and brazing on the stainless inserts...

Here are all the parts before assembly and brazing...
The drop outs fitted into the fork legs...

I went through 2 drill bits to finally get the crown drilled for the brake bolt...



here is my home made paint booth, it actually did such a good job I feel like I could paint a whole frame in it... but I think I will come up with a bigger booth for that...
The white above is the direct to metal primer coat... and the black below is the base coat for the deep black finish.

The final coat of black color before the clear coat goes on...
Here is the fork crown after clean up with the clear coat finish and the brake bolt installed...

The drop outs with a polished finish...
And lastly a few shots Debi took of the fork installed on here bike... Looks pretty good. I like the pencil thin fork legs, this fork looks fast!

Debi's mechanic said the fork went on with out a hitch... like it was built for the frame. Well... it actually was built for the frame.
Well I enjoyed making this fork and it looks like I have another one to build for a new customer.
I will update it soon.

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