Coupster, yes, I am familiar with Hero and I actually went there last year to meet Pam who was kind of enough to show me their process. I highly recommend a visit to Greensboro AL and Rural Studio if you are out there.

The orthotape is very heavy duty. Here is the link to Calfee's supply. I used Orthoptape.com for mine. Most brands are similar enough but some brands have different sanding characteristics.

DIY Kit - CALFEE DESIGN

Under DIY Kit you will find all the materials sold separately. Calfee's supply of bamboo tubes is superior for future reference.

I miter my bamboo tubes to the aluminum or steel head tube, seat tube and bottom bracket but I also put in basswood gussets for additional stiffness.

The balsa lug method would probably work fine and in fact I used that method first with the orthotape. I never rode that frame since it was more a test but in general the orthotape is plenty strong enough.

I've been riding the one on my blog on gravel and paved road. It has held up fine. I'm in the Asheville area. Let me know if you need any help or have questions during your build.

Enjoy!