Thread: Lug Making
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Old 06-24-18 | 07:56 PM
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Andrew R Stewart
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Joined: Feb 2012
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From: Rochester, NY

Bikes: Stewart S&S coupled sport tourer, Stewart Sunday light, Stewart Commuting, Stewart Touring, Co Motion Tandem, Stewart 3-Spd, Stewart Track, Fuji Finest, Mongoose Tomac ATB, GT Bravado ATB, JCP Folder, Stewart 650B ATB

Lug Making

I've only made a couple of lugs before, a number of years ago, before I decided to go fillet for most of my frames. So looking for a new project a custom lugged urban station wagon bike seems right. This will be a long time job. Making what is a second mainframe for all intents takes a while. I started with the frame geometry and tube dimensions. Then got .058" walled tubes that are .125" larger an OD (to allow the frame tubes to slip inside with nice brazing clearances). Mitered to angles, tacked and fillet brazed then began the slow filing step. Out of the first batch of 3 DT/HT blanks 1 was nice enough to continue with.

Here's a couple of shots of the beginning. I've applied navel jelly to enhance the fillet/steel difference. More to come as I get to it. Andy
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