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  1. #1
    Senior Member Cassave's Avatar
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    How to build a lugged steel frame, with pics

    I've had a few people suggest that since I'm building a new frame why not document it in a
    thread. So, for those that might be interested here's how a lugged steel frame goes together.
    I know some of you have barely or rarely seen lugged steel frames but this is how bikes have been
    put together for over a century.


    I'm using a Deddaccia Com12.5 tubeset, Henry James lugs and drops, Everest crankshell
    and a full sloping stainless fork crown.
    The head lugs and fork tips and drops will be high polish.


    First thing is to braze the seat tube and crankshell. I've added some stainless
    cable guides to the crankshell.


    Next, miter the downtube/headtube joint...


    A fitup with the lower headlug, more lug filing to do before brazing...


    Here's the lower headlug brazed and polished and the toptube mitered and
    fitted up.........


    And the toptube/seat tube miter fitted up...


    As it looks in the jig. Toptube ready for flux.........


    Black flux on the headlug since it's stainless..


    White flux on the seatlug since it's all alloy steel...


    The seat lug brazed and cooling off. The flux is now a glassy coating that's
    starting to crack..........
    Last edited by Cassave; 02-20-12 at 11:06 AM.

  2. #2
    Senior Member Cassave's Avatar
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    Moving on...............


    Upper head lug brazed and the flux washed off, ready to file the lug shoreline.


    The front of the main triangle. Lower head lug polished, upper head lug
    filed and almost ready to polish.....


    The main triangle, brazed. Head and seat tubes not yet trimmed.


    I'll build the fork next. Prepping the crown.
    Last edited by Cassave; 02-20-12 at 11:09 AM.

  3. #3
    How much does it weigh? prendrefeu's Avatar
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    Wow.... Great work, and thanks for documenting!

    and what are your prices?
    Weight weenies keep it light.

    Director of the Midnight Express Ride; Board of Directors, Los Angeles County Bicycle Coalition.

  4. #4
    My bicycle is fixed Brian Sorrell's Avatar
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    Very nice pics. Can you talk about your experience leading up to this project -- e.g., other metalworking skills that you have, special tools, have you built bicycle frames before (I assume that you have), etc.

    (For my money: lugged steel is as beautiful as a bicycle frame gets.)

  5. #5
    Senior Member Cassave's Avatar
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    Quote Originally Posted by prendrefeu View Post
    Wow.... Great work, and thanks for documenting!

    and what are your prices?
    Thanks, but not for hire.

  6. #6
    hello roadfix's Avatar
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    Is that the 53 you're putting together for me? So far so good!

    Thanks for posting, this is very interesting. I wish I had the tools and the skills to do this.

  7. #7
    Semper Fidelis
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    wow,really cool,please keep showing the pictures/process .
    "Advantages Must Be Pressed, Disadvantages Must Be Overcome"

  8. #8
    Senior Member Cassave's Avatar
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    Quote Originally Posted by Brian Sorrell View Post
    Very nice pics. Can you talk about your experience leading up to this project -- e.g., other metalworking skills that you have, special tools, have you built bicycle frames before (I assume that you have), etc.

    (For my money: lugged steel is as beautiful as a bicycle frame gets.)
    This is frame 60 something. I built the first one about 1975.

    Special tools? Not much. Homemade fixtures and fork blade
    bending tool (more pics coming).

  9. #9
    Pedal pusher... alicestrong's Avatar
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    Thank you. That is an amazing process...
    May you live long, live strong, and live happy!

  10. #10
    Senior Member VanceMac's Avatar
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    I'm not sure I understand... is this the mold, over which you will lay the carbon fiber?

    But seriously, can't wait to see it. Color scheme?

  11. #11
    aka. vertical jon WhiteCarbonDude's Avatar
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    Quote Originally Posted by Cassave View Post
    Thanks, but not for hire.
    Not fair!

  12. #12
    Senior Member Cassave's Avatar
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    Quote Originally Posted by VanceMac View Post
    I'm not sure I understand... is this the mold, over which you will lay the carbon fiber?

    But seriously, can't wait to see it. Color scheme?
    That is literally the toughest decision I ever make with these things, the rest is
    easy.

  13. #13
    Embracing the fredness herbm's Avatar
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    Wow....thanks Steve....very very cool...and extremely interesting!!!
    Wheel Sucker Extraordinaire

  14. #14
    Senior Member
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    Right, so BF maintenance/frame ogling party @ Steve's!!!!

  15. #15
    Senior Member
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    How/where/when did you learn this stuff?

  16. #16
    Senior Member GP's Avatar
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    Best thread ever.

  17. #17
    just keep riding BluesDawg's Avatar
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    NICE!!!
    The more you ride your bike, the less your ass will hurt.

  18. #18
    Senior Member Cassave's Avatar
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    Quote Originally Posted by gr@sshopper View Post
    Right, so BF maintenance/frame ogling party @ Steve's!!!!
    So very very wrong.

  19. #19
    Senior Member Cassave's Avatar
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    Quote Originally Posted by gr@sshopper View Post
    How/where/when did you learn this stuff?
    Just dove in (a long time ago).
    Like pancakes, the first one's never so good.

  20. #20
    got the climbing bug jsigone's Avatar
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    great pics!!!

  21. #21
    Pedal pusher... alicestrong's Avatar
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    PINK
    May you live long, live strong, and live happy!

  22. #22
    Senior Member thomson's Avatar
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    Beautiful Steve.
    .

  23. #23
    Senior Member Cassave's Avatar
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    Quote Originally Posted by alicestrong View Post
    PINK

    NOT PINK.

  24. #24
    aka. vertical jon WhiteCarbonDude's Avatar
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    Quote Originally Posted by Cassave View Post
    That is literally the toughest decision I ever make with these things, the rest is
    easy.
    I would go with copper plate.

  25. #25
    Pedal pusher... alicestrong's Avatar
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    Quote Originally Posted by Cassave View Post
    NOT PINK.



    Now how did I guess that you might say that?

    But seriously, thank you. I know when I first read here that you built bikes I was very curious but I never did make it over to the Framebuilders subforum so thanks again for putting this together...

    Now when they get that hemp based frame material perfected...
    May you live long, live strong, and live happy!

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