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-   -   How to build a lugged steel frame, with pics (http://www.bikeforums.net/framebuilders/399311-how-build-lugged-steel-frame-pics.html)

Cassave 04-04-08 12:17 PM

Quote:

Originally Posted by magicant (Post 6461441)
Beautiful pics, Steve.

The text however =
http://image.linotype.com/support/howtouse/04_EN.gif

Greek to you?

Cassave 04-09-08 09:51 AM

Ok, moving on. Starting to look like a bicycle frame.

http://i1145.photobucket.com/albums/...ays_fluxed.jpg
http://i1145.photobucket.com/albums/...ys_fluxed2.jpg
The chainstays and chainstay bridge fixtured, fluxed and ready to braze.

http://i1145.photobucket.com/albums/...ays_brazed.jpg
Brazed and cleaned, ready to file.

http://i1145.photobucket.com/albums/...tays_filed.jpg
Nice. Done with all the heat in this area so I'll chase the crankshell
threads.....

http://i1145.photobucket.com/albums/...ve/bb_taps.jpg
Here's the bottom bracket tapping tool. Set up with English taps,
left side= right hand thread, right side = left hand thread.

http://i1145.photobucket.com/albums/...eadchasing.jpg
Cleaning the threads of excess brazing alloy.

http://i1145.photobucket.com/albums/...ve/bb_done.jpg
Threads ready for a bottom bracket, I'll face the ends last, just before
paint.

Now on to the seat stays and brake bridge.......

DScott 04-09-08 01:11 PM

Clint,
Great posts! So very interesting, and much appreciated.

What do you think about the stainless steel tubesets, like the Columbus XCr tubeset used by Pegoretti for his Responsorium? Do you think this material has utility, and how hard is it to use stainless vs. regular steel tubesets?

Cassave 04-09-08 02:24 PM

Quote:

Originally Posted by DScott (Post 6489886)
Clint,
Great posts! So very interesting, and much appreciated.

What do you think about the stainless steel tubesets, like the Columbus XCr tubeset used by Pegoretti for his Responsorium? Do you think this material has utility, and how hard is it to use stainless vs. regular steel tubesets?

As far as I know, the Columbus tubes are made from a Carpenter Steel, 400 series alloy.
It was designed as a forging alloy, not for drawn tubes. The materials are fine to work with,
but a bit tougher on cutters due to the high nickel and chromium levels. Brazing is no problem
with the right fluxes.

mrbisoy 04-09-08 03:29 PM

I don't have the time nor the skills to do anything close to this, but thank you just the same for a very informative thread.

Cleave 04-09-08 06:35 PM

Quote:

Originally Posted by Cassave (Post 6488555)
Ok, moving on. Starting to look like a bicycle frame.

Hi Steve,

This has always looked like a bicycle frame to me -- a very nice bicycle frame.

Cassave 04-14-08 10:04 AM

The work progresses. I finished the rear triangle.
The one spot that framebuilders typically try to make a signature design is
the seat cluster. It's a very low stress location on diamond frames so it offers
a lot of possibilities for variation. The design I prefer is the one here. I've
built several frames with the same very clean modified fastback design.

http://i1145.photobucket.com/albums/...eat_stays1.jpg
Fitting up the stays. Some profiling still to be done.

http://i1145.photobucket.com/albums/...eat_stays2.jpg
The fairly complex shape that needs to be filed into the top of the seat stays.

http://i1145.photobucket.com/albums/...eat_stays3.jpg
Getting there..........

http://i1145.photobucket.com/albums/...eat_stays5.jpg
Fluxed and ready to braze.

http://i1145.photobucket.com/albums/...eat_stays6.jpg
Brazed and cooling.

http://i1145.photobucket.com/albums/...e/cluster2.jpg
http://i1145.photobucket.com/albums/...e/cluster1.jpg
There, cleaned, filed and showing the finished brake bridge as well.

http://i1145.photobucket.com/albums/...ve/bosses1.jpg
Added the front derailleur boss and two pair of bottle bosses as well.

Next, on to the small braze-ons. Cable stops and guides.

Pepper Grinder 04-14-08 10:09 AM

Quote:

Originally Posted by Cassave (Post 6488555)
Threads ready for a bottom bracket, I'll face the ends last, just before
paint.

I thought facing was best done after painting?

roadfix 04-14-08 10:19 AM

Following progress. Looking good!

HAMMER MAN 04-14-08 10:24 AM

just outstanding and the process with the pictures is really super-cool.

OC Roadie 04-14-08 10:32 AM

This has got to be one of the coolest most worthwhile threads I've ever seen on here.

Cassave 04-14-08 10:39 AM

Quote:

Originally Posted by Pepper Grinder (Post 6516502)
I thought facing was best done after painting?

Facing after paint tends to chip the paint on the circumference of the BB shell.
Only the fixed side cup actually interfaces with the end of the BB shell. The non-drive side
cup sits inside the thing with the end of the shell showing.

I just take a razor blade and remove the paint on the end of the fixed side before installing the
bottom bracket.

Fat Boy 04-14-08 11:19 AM

Are you using one of Henry James' frame jigs?

mtblurkr 04-14-08 11:23 AM

This is a great thread. Thanks!

Cassave 04-14-08 02:16 PM

Quote:

Originally Posted by Fat Boy (Post 6517025)
Are you using one of Henry James' frame jigs?

No. All my tooling is homemade. Most of it's older than
Hank's line of jigs.

Cassave 04-14-08 02:18 PM

Quote:

Originally Posted by mtblurkr (Post 6517053)
This is a great thread. Thanks!

My pleasure, glad you like it.

tinrobot 04-14-08 07:52 PM

I love that seat cluster, beautiful work.

MTBMaven 04-14-08 10:53 PM

+1 on the seat cluster. That is beautiful. Can't wait to see the paint scheme. Any thoughts since the last time you commented? Wet or powder? If I remember the lugs are going to be polished right?

alicestrong 04-15-08 07:45 AM

Beautiful! My kind of bikey! :D

Cassave 04-15-08 09:37 AM

Quote:

Originally Posted by MTBMaven (Post 6519979)
+1 on the seat cluster. That is beautiful. Can't wait to see the paint scheme. Any thoughts since the last time you commented? Wet or powder? If I remember the lugs are going to be polished right?


Definitely wet (automotive acrylic urethanes with clear coat).
Probably 2 color and yes the head lugs, dropouts and fork crown are polished stainless.

I'll tryout some custom decals using the Pappilio waterslide paper I just found.

pv0463 04-16-08 09:08 AM

C'mon, man...ease up! this is like freakin' torture! Home-made tooling, an original design where allowable (seat cluster), all steel construction, polished stainless lugs, wet pai....
Sorry, I have to go wipe myself now.
But seriously, will there ever be a right price for it??? Please?

Cassave 04-16-08 10:35 AM

Quote:

Originally Posted by pv0463 (Post 6528456)
C'mon, man...ease up! this is like freakin' torture! Home-made tooling, an original design where allowable (seat cluster), all steel construction, polished stainless lugs, wet pai....
Sorry, I have to go wipe myself now.
But seriously, will there ever be a right price for it??? Please?

Ah, you never know.

I'll build it up and see how I like it.

chimivee 04-16-08 11:05 AM

Awesome thread. Great pics. Excellent work.

This photo is brilliant!
Quote:

Originally Posted by Cassave (Post 6435538)


Cassave 04-16-08 04:19 PM

A few more shots from last evening.........


http://i1145.photobucket.com/albums/...ableguide2.jpg
The brake cable guides brazed to the top tube.

http://i1145.photobucket.com/albums/...ableguide1.jpg
A close up of one, the flux starting to crack as it cools.

http://i1145.photobucket.com/albums/...dcablestop.jpg
And the rear derailleur cable stop (on the bottom of the driveside chainstay.

Next come some homemade parts; chain hanger pin, shifter cable stops
and stainless wire bottle cages (similar to Nitto). Stay tuned...

voltman 04-16-08 04:27 PM

Is it wrong that I'm almost as equally impressed that you're making your own cages as I am about the frame itself?


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