I had a nice day sculpting and hacksawing. I'm happy with the results. This lug set has more flowing lines and less clutter then the first set a year+ ago had.

Marking out the center lines. No need to be precise as I repeat with the blank on it's other side and ail the prick punch in-between the close together lines if I was off center height a tad.



The holes have been drilled. Slight different diameters for the different tube diameters. I went in steps to better keep the holes on the center lines.


The removal starts! I'm not the best with a hacksaw but they sure are efficient for what they can do. Each head lug has, maybe, 16 cuts to trim off the bulk.


After the hack sawing, the lower lug isn't yet done with that, comes the bench grinder's "contribution". Some sculpt ice with chain saws, I do metal on the grinder


I spent some time thinking the carving process and sequence to best be able to hold the lugs while doing this or that. I decided to do the HT portion first. As I felt that the DTTT sockets are easier to file and suffer less with limited lug holding. I also did the same step on one lug then the other to maintain similar shaping. Here one has the HT lines nearly done and the other is only grinder roughed out. The DT and TT IDs are ground out to freely slide in the actual frame tubes, the hole saws leave a slight necking at the head tube interface needing removal.


Now the second socket is done. here the grinding rough in is shown. Good thing I have hippy finger tips and some cooling water next to the grinder.


Both head lugs are done, or about 95% done. Some minor ID fit up and shoreline smoothing remains.



The ST/TT blank comes next but it will take more time. The binder will get attached then the TT socket carved. The ST portion will wait for the fit up of the main frame and seat stays to insure the stays attach to the lug and it's skirt is determined. Andy