Thread: Lug Making
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Old 12-05-18 | 11:01 PM
  #19  
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Andrew R Stewart
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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

Today I patched a couple of pocks in the blanks' fillets, drilled some holes and did the initial cut lines. One issue I have discovered is that the headtube I intend to use is a tad smaller then it should have been, so after reaming for the headset cups it's walls would be around .5mm thick. A tad thin for my tastes. So what I've decided to do is to widen the head lugs' bands that wrap around the HT so they are wider then the cup's skirts are deep, by a few mms. I will have to be careful how deep the reamer goes, not hard to do. But I won't be able to use the facer part as this would result in too deep a reaming (the headset cups skirts are under 10mm deep and the reamer goes about 17mm in to have the facer engage). I'll use a hand file and a square to insure a square face. Just like I did for the first few frames I made in 1978.

Here's a shot of current progress. The big holes are visual lightening ones. The medium ones on the HT sides are where shoreline corners will be (approximately) The tiny ones on the tube centerlines will be aesthetic ones at the ends of short tangs, which will be rounded off and not pointy. Like I said I'm going for a sort of art deco look. The Sharpie lines are approximate shoreline edges. The HT portions have the end face and the band widths scribed. Andy

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