Framebuilders - Bamboo frame Worklog [MADE IN BRASIL]

Hello everyone!
First I want to thank you all for the inspiration for this project. I've been browsing the forums for some time now, found some awesome topics about bamboo frames and realized it coudn't be THAT hard.
So, to make things harder (and because carbon fiber is so expensive here - its like U$$120,00/m² + shipping) I decided to go with Fiberglass

(FULL SIZE PICTURES IN MY FLICKR: here (http://www.flickr.com/photos/malk4vi4n/sets/72157624407236902/))


So.. I started shopping for bamboo and found these:
http://farm5.static.flickr.com/4093/4754865687_ec7bb9b091_z.jpg
Some regular stuff and some Nigra for the stays. The big one? It is going to become a fork in a near future.


Heating the pieces of Bamboo:
http://farm5.static.flickr.com/4093/4754867095_3acbb406a6_z.jpg
http://farm5.static.flickr.com/4137/4754867527_cc0b7897e8_z.jpg


Sanded:
http://farm5.static.flickr.com/4117/4754868439_dfbfa66cc9_z.jpg


So I browsed Cannondale website and got the Supersix dimensions, translated into AutoCAD and cutted the pieces at aprox sizes:
http://farm5.static.flickr.com/4114/4754869167_406723dfa4_z.jpg


So far so good huh?! Okay but there's a problem. I can't get the right TUBES, dropouts and stuff here in Brasil. Yeah, we don't have (http://www.cycle-frames.com/) and I was in no mood to import metal tubes from the US. So I started working with what I had in hands: FIBERGLASS.

First I decided to integrate the bottom bracket in the structure of the frame. I started by laminating 3 layers of fiberglass to the bottom bracket so it would absorb the impacts it is going to be submitted:
http://farm5.static.flickr.com/4122/4754871551_97aa8d7f1a_z.jpg

http://farm5.static.flickr.com/4078/4754872027_8f940729fa_z.jpg
It sure fells stiff but I can't help thinking how long will it last.

For the head tube I got a piece of bamboo and stuck the main head parts in it. Will laminate some fiberglass in it. And for the rear dropouts I made a mold of my main bike and I'll laminate it with fiberglass and some internal metal reinforcements (surprise for the upcoming posts).

This post's final picture include the finishing-pending bottom bracket and my solution for the head tube as well as the MOLD for the rear dropouts.
http://farm5.static.flickr.com/4074/4754864729_8583d1d773_b.jpg


Tomorrow i'm gonna finish the rear dropout mold and hopefully laminate a couple dropouts and the head tube.

(more pics here (http://www.flickr.com/photos/malk4vi4n/sets/72157624407236902/))
Sorry for the "rusty" english, now COMMENT! :D:D

This is an amazing thread. You may need to make the surface of the tubes rough for the resin to soak in. I am looking to how the lugs are laid up.

Yes yes, will do! I'll also add some fiber inside some of the tubes, near the joints. Something like this guy did: http://picasaweb.google.com/alansutton/Bamboo1#5384026423327444258
i'm thinking of using air baloons to keep the fiber under pressure against the walls.

Dammit!
Last night I laminated a fiber rear dropout in a epoxy mold and stuck some metal reinforcements. So today I checked and it was crap. The rear dropout didn't quite came out of the mold and it was so weak. It came apart and I even got my metal from it after some smashing and cracking.
S*** happens when ur a noob at anything right?! I think the fiber din't "bent" around the metal and some corners as it should so weak spot were created.

So I came up with the plan B, witch is less complicated and sounds stronger as this time I will wrap the fiber around metal and bamboo and there will be no hard corners. Sorry to say u'll have to wait for the pictures for I'm late for some stuff right now and gotta go.

Looks awesome bro, I cant wait to see these drop outs! I think that the look of fiber glass and metal reinforcements would have looked really cool, i gotta see where you going with it!

Thank you for the support and good vibes!


Picture time :thumb:

Here are some metal and the mold that didn't work. There are 7 metal strings in each cable section. (these are old "cables", I made new ones and they show in following pictures)
http://farm5.static.flickr.com/4122/4767976791_ff4bf86f23_z.jpg


I call this Plan B. Let me explain how I'll do it;

Get the main triangle of the frame glued up in place
Fill the mold with resin and metal
Get fiber and resin around those metal strings and stick them inside the bamboo chain and seat stays
Glue and laminate it all together while it's positioned in a hub. The hole thing will be straight and aligned hopefullyl. (sorry, I guess there will be no metal to SEE when done)

http://farm5.static.flickr.com/4134/4768613666_b95f72337d_z.jpg


The alignment of the center of the nut is quite good with my bike's.
http://farm5.static.flickr.com/4137/4767973625_f5f1662bc5_z.jpg
http://farm5.static.flickr.com/4123/4768059069_8a7e2e51fb_z.jpg



Here's the head tube ready for laminating (first task of the day).
http://farm5.static.flickr.com/4102/4768614322_7494814883_z.jpg



And an exclusive shot of my board.
http://farm5.static.flickr.com/4095/4768610644_1da60a2388_z.jpg



Her name is Phoebe and she's the parts donor (and 2nd ride).
http://farm5.static.flickr.com/4137/4768696344_9927a8ec2e_z.jpg



Lets hope the bike holds it together!:D

HA! Plan B is no more. Moving on to plan C (the first decent one if you think about it). Bought a couple of these and you can figure out the rest:
http://farm5.static.flickr.com/4097/4775286262_54c6278daf_z.jpg


Now moving for the next stage of the build: Cut and paste
http://farm5.static.flickr.com/4079/4774653971_d7e6e48b49_z.jpg


Doing some work on the tubes. Boring...
http://farm5.static.flickr.com/4096/4775285286_a531e1951d_z.jpg


Let the dremel tell ya
http://farm5.static.flickr.com/4097/4774648133_8557ac1642_z.jpg



Soo...Last night I had some friends over and we got enthusiastic so there you go, little shot cups:
http://farm5.static.flickr.com/4123/4775288528_e3f05c4b00_z.jpg




Wish me luck. And reply goddamit!

Nice, it looks good. Hope it rides well. Always fancied treating myself to a bamboo bike when I can afford it!

First off, the shot glasses are awesome, perfect way to use up scraps I reckon! As for the bike build, I hugely impressed but what you've done so far, so much so I've found a clump of bamboo that I plan to hack down this weekend so that I can make a start myself. Please keep posting pictures, very inspiring!

love the shot glasses, can't wait to see the finished bike. keep going!

did you use fiberglass for those shot glasses?

awesome build thread and please more pix!

did you use fiberglass for those shot glasses?

awesome build thread and please more pix!

Pure bamboo and some varnish finish. No fiber.

Thank you all for the replies! Tomorrow I'll take more pictures.
Thinking bamboo cable stops...

I am so happy right now!

Pictures are better than words. In a process that took me some 19 hours I aligned and glued all stuff together for laminating tomorrow.

http://farm5.static.flickr.com/4142/4780913094_90cf329c5e_z.jpg

http://farm5.static.flickr.com/4101/4780912130_3d3e979611_b.jpg


Front. Final job;
http://farm5.static.flickr.com/4135/4780278219_9cc4191d92_z.jpg

http://farm5.static.flickr.com/4121/4780278663_ee31fff552_z.jpg

http://farm5.static.flickr.com/4075/4780279143_6ab3920730_z.jpg


As you can see I already put some fiberglass in some spots where it was difficult to cut the bamboo in proper shape
http://farm5.static.flickr.com/4094/4780914996_f296bd14f6_z.jpg


Sticking with plan C!
http://farm5.static.flickr.com/4116/4780280097_b384c40bf6_z.jpg

http://farm5.static.flickr.com/4073/4780280675_f581881379_b.jpg



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And last but not least, the preview of the beast:
http://farm5.static.flickr.com/4077/4780276151_44b63a9efa_b.jpg

Make sure your rear dropouts are lined up. Put a wheel in if you can do it without breaking anything. I tried doing it like you have shown here, and my dropouts were not lined up right. One was a little bit further back than the other, which made it extremely difficult to put the wheel in.

Wow! so awesome. I can't wait for the bamboo I'm going from seeds is big enough to make something out of.

Very inspiring thread!

Make sure your rear dropouts are lined up. Put a wheel in if you can do it without breaking anything. I tried doing it like you have shown here, and my dropouts were not lined up right. One was a little bit further back than the other, which made it extremely difficult to put the wheel in.

Thanks for the tip. I will test it tomorrow before laminating.

Today I'm doing some final alignment. The central hub was off and the head tube had a side angle on it. Now is the time for final adjustments before laminating so I also replaced the chain stays for some stronger bamboo. Better safe than sorry.
Now, back to work.

Well done ... :thumb:

Do you have epoxy putty available in Brazil ... retail name of JB Weld?
This stuff is a two part compound that would be perfect to reinforce some the high stress areas in your frame.

http://www.peterverdonedesigns.com/images/content/motorcycle/CRASH/IMG_5882.jpg

Well done ... :thumb:

Do you have epoxy putty available in Brazil ... retail name of JB Weld?
This stuff is a two part compound that would be perfect to reinforce some the high stress areas in your frame.

http://www.peterverdonedesigns.com/images/content/motorcycle/CRASH/IMG_5882.jpg


Hey, what do you think THIS is? Always in the box! Its called Durepoxy around here.
http://farm5.static.flickr.com/4134/4768613666_b95f72337d_z.jpg


Im actually going to reinforce all the corners with it, the fiberglass isn't that good on corners.

Please could you post the sizes of the bamboo pieces you using? As in diameter and if possible wall thickness. I literally walked into a nearby bushy area and hacked out some bamboo, some of it really big and some a little on the small (I think).

Picture time! Uploading. ..

Okay fellas, sorry for the long time between posts. I am a damn perfeccionist and it was very hard to get satisfied with the alignment of my bike. I mean I worked like a dog on this, but now is good to go.
Pictures!

This is the final alignment stage where I glued the stays in place.
http://farm5.static.flickr.com/4119/4797878370_c4059406bb_z.jpg


Is as good as it gets
http://farm5.static.flickr.com/4101/4797878946_3da47fbf8a_z.jpg


My good old tire as I wait for the bike to dry before placing the rear dropouts
http://farm5.static.flickr.com/4077/4797879520_e25d1987b8_z.jpg


My friend working on a 198X Caloi 10
http://farm5.static.flickr.com/4143/4797253357_e70a940366_z.jpg


This is Vin Diesel thinking "Holy sh*t.."; Fast and Furious is on.
http://farm5.static.flickr.com/4123/4797254497_79fdde4336_z.jpg


Looking good or what? The rear wheel is sooooo close to the seat tube: 1.35cm
http://farm5.static.flickr.com/4093/4797254045_33c1f38fbf_z.jpg


From the back
http://farm5.static.flickr.com/4074/4797882814_d97499fa32_z.jpg


Its in place. Now I have to laminate. Tomorrow morning maybe.
http://farm5.static.flickr.com/4122/4797883298_3d6c189177_z.jpg

Please could you post the sizes of the bamboo pieces you using? As in diameter and if possible wall thickness. I literally walked into a nearby bushy area and hacked out some bamboo, some of it really big and some a little on the small (I think).

I just used some good sense. Take a aluminium bike as model and look for the right diameter. As for wall thickness, it varied for each tube around 2.5 - 3.30mm, being the large ones the seat and bottom tubes

I just used some good sense. Take a aluminium bike as model and look for the right diameter. As for wall thickness, it varied for each tube around 2.5 - 3.30mm, being the large ones the seat and bottom tubes

Awesome job! I have to admire someone who doesn't just post "How do I....?" questions and just gets after it and starts building.

My only observation/concern:
Seems like using metal tubes to get your tubing diameters might not be the best solution- I've never done a bamboo bike, but the ones I've seen on this forum all use bigger diameters than what you're using.

The proof will be in the finshed frame though- can't wait to see it!

Awesome job! I have to admire someone who doesn't just post "How do I....?" questions and just gets after it and starts building.

My only observation/concern:
Seems like using metal tubes to get your tubing diameters might not be the best solution- I've never done a bamboo bike, but the ones I've seen on this forum all use bigger diameters than what you're using.

The proof will be in the finshed frame though- can't wait to see it!

My objective is to build it lighter than my aluminium bike, lets see how it handles the road.

Hello everyone, missed me?
Anyway, I'm taking a little longer to lay up the fiber beacause I want it to be perfect. I'll let pictures do the talking:

The frame after main reinforcement. There will be another layer of fiber for aesthetics before finishing;
http://farm5.static.flickr.com/4086/4831306226_d3ec1c9761_z.jpg


The fork tube;
http://farm5.static.flickr.com/4149/4831306654_bd43019c64_z.jpg


The bottom. There will be more layers here;
http://farm5.static.flickr.com/4087/4831307248_4ce16f89a4_z.jpg


From another angle;
http://farm5.static.flickr.com/4102/4831309318_98d36ef91e_z.jpg


The top section. Already sanded for the final layup that will cover a bigger portion of the seat stays. As soon as I measure the break tube size and position with the weels on;
http://farm5.static.flickr.com/4105/4831308444_4e19997dd4_z.jpg


The left rear Dropout. I'll sand it today and find out if its tight enough;
http://farm5.static.flickr.com/4145/4830695755_cf1ccb90e7_z.jpg


Aaaaand the right one, witch was compressed after lay up;
http://farm5.static.flickr.com/4074/4831311086_3a4373b2f2_z.jpg


This is the reason working with fiber is a pain in the a$$. It would be easier with a Carbon tape but thats part of my challenge;
http://farm5.static.flickr.com/4111/4831313680_7357d85a13_z.jpg

Get some electrical tape and wrap the lugs after you've applied the glass and resin. That will pack it all down flat and make things much neater and stronger.
It will peel off cleanly after the Epoxy cures.
Just make sure you start wrapping the tape up the bamboo well away from the wet Epoxy to anchor it and then just spiral it down to the lug. That way you're not just spinning the materials around and pulling everything out of place.

Get some electrical tape and wrap the lugs after you've applied the glass and resin. That will pack it all down flat and make things much neater and stronger.
It will peel off cleanly after the Epoxy cures.
Just make sure you start wrapping the tape up the bamboo well away from the wet Epoxy to anchor it and then just spiral it down to the lug. That way you're not just spinning the materials around and pulling everything out of place.

I wish you told me that 2 days ago! I figured it out after a while but didn't use electrical tape. I'll take some pictures tomorrow, maybe after I finish the work with fiber.

Sorry. You can always rasp and sand most of it away and apply a second layer.

wow man your really inspiring me to start working on my first bike project. Not building my own frame, but I will be taking a 71 Peugeot frame and sanding and repainting it to my likings... I cant wait to see the final product, keep up the good work!

Hey guys, guess who took me for a test drive on my garage today!
http://farm5.static.flickr.com/4080/4927973446_656921b1c1_z.jpg

I'll apply a layer of GelCoat to it soon.

Well done ... post a few detailed photos before and after the gel coat :thumb:

Was not sure how you were going to streagthen the ends untill I got to the end of the thread. Are you going to smooth out the fiberglass and paint them so thay could look like one piece? that would look nice.

BTW, Carbon fiber and kevlar are tough. But, would jbweld used as a epoxy applied to carbon fiber make it that much more stronger? has anyone done this?

Epoxy used for composite construction has to wet out the reinforcing material. JB weld does not wet out fabric and in fact I don't believe it has strength properties any greater than other epoxies.
There is a reason they have such a broad range of specific epoxies for composite construction.

More pics?

Ppl been asking for pictures and though I didn't had much time to work on it latelly, here it goes:

Full shot of the bike
http://farm5.static.flickr.com/4113/5018765485_524dc74f27_b.jpg


Detail on my broken shifter support. The problem was that the hole for the screw to enter wasn't deep enough so as I screwed it in harder, it was pushing the hole thing out.
http://farm5.static.flickr.com/4130/5018765119_80aeb42550_b.jpg


Detail on my improvised dropouts. They worked out fine.
http://farm5.static.flickr.com/4150/5018764861_330afc286a_z.jpg


The "cable guide" under the BB. When I apply the GelCoat I will dig it deeper.
http://farm5.static.flickr.com/4151/5019369976_254c2f8511_z.jpg


And that's why I regret integrating the BB in the frame, I ended up using a kinda narrow one.
http://farm5.static.flickr.com/4133/5018764323_f38d376ab6_z.jpg


The seat part. I'm proud of the brake fit, its working great.
http://farm5.static.flickr.com/4152/5018764075_5781c8904a_z.jpg


Front section. Maybe my top tube has too thin walls (I used ~2mm), I don't trust sitting on it but it sure looks beautiful.
http://farm5.static.flickr.com/4153/5019369342_6df39b9995_z.jpg


It will look great after I apply GelCoat to the lugs and varnish the bamboo.
http://farm5.static.flickr.com/4130/5018763503_9dbdbd34a8_z.jpg

And for the Bamboo 2.0 I'm designing my custom metal lugs. It will be a mountain bike and the lugs have 3mm walls (except for the seatpost clamp area) what do you think?
http://farm5.static.flickr.com/4129/5018762987_cb3dc0e842.jpg

http://farm5.static.flickr.com/4106/5019368346_9fb19eede1.jpg

http://farm5.static.flickr.com/4127/5018762965_a7c745db6d.jpg


And finally the yet unfinished dropouts. Does anyone know the threading pattern for the caliper mounting holes on a disc brake system?
For me, it looks elegant.
http://farm5.static.flickr.com/4130/5019368314_daa93847d2_b.jpg

It will use 5mm thick 6061 Alu. And the next set will have a integrated seatpost clamp at the respective part.


Thoughts, suggestions?
My best.

Sweet, how are u going to make the lugs? CNC?? casting? Wonder if a set of grafftek lugs will work fine in your built.

Sweet, how are u going to make the lugs? CNC?? casting? Wonder if a set of grafftek lugs will work fine in your built.

I'm having them made for me, CNC I guess. I designed the lugs specially for the chosen bamboo width with a margin to make heavier or lighter bikes.
Have in mind that nobody sells lugs, tubes or any kind of frame parts here in Brasil.

I know, years ago the brazilian team bikes where made by a master builder in chile. There u have a niche :D

Hey guys!
Better late than never right?!

check this out!

http://www.youtube.com/watch?v=yzpd7uLV-Oo
theres more pics of her in my flickr: http://www.flickr.com/photos/malk4vi4n/sets/72157624407236902/

Mountain bike coming soon!

Looks great! Are you still planing on making a fork out of the really wide diameter bamboo? I'm interested to see if that would work.