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A Long Time Coming

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A Long Time Coming

Old 10-17-20, 06:46 PM
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Andrew R Stewart 
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A Long Time Coming

My first MtB frame and fork begins in earnest, after about 45 years of thinking about building one. Dual rigid, 650B by 2.5/2,6 wheels. This build will go slowly as there's a lot I still have yet to figure out. For now here's the best photo I have as yet. The blades have been cut down, home made drop outs are brazed in and the top ends of the blades mitered to just touch on the fork's centerline. The plan is to braze the tops together to maintain their alignment during the hole sawing for the steerer miter. Andy
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Old 10-18-20, 01:39 AM
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Looking good! What kind of brakes are you planning for? A mistake I made on my first fork was having nice far-apart blades for plenty of tyre clearance-- everyone wants huge tyres these days right-- and then finding that V-brake bosses 120mm apart just aren't going to work.
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Old 10-18-20, 08:10 AM
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This bike will use disk brakes. I agree with the current trend to fatter tires, I predict skinnier will once again become fashion in 5+ years Andy
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Old 10-18-20, 08:12 AM
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v brakes are never coming back. Not sure about narrower tires either, the roads aren't fixing themselves.

I like that fixture
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Old 10-24-20, 08:45 PM
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I joined the top edges of the blades together (a butt braze) a few days ago, then cut the steerer miter today. I have more details on my Flicker album https://www.flickr.com/photos/731955...57716507964431

The shop is closed this week (we have been doing a week off in mid fall for a few years now, really need it this year!) so more on the fork work will get done soon. But the frame will wait for a computer servicing. I have gained some gremlins, or lost some settings..., recently. I blame the Ruskies and my early voting by mail Bike Cad won't open. At least I now have my A-C dimension down to a specific number. Andy
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Old 10-25-20, 02:47 AM
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Always a good idea to make the fork first anyway because then you can measure the axle to crown and if necessary adjust the frame design if it's not exactly what you were shooting for.

On the Flickr you said 0.5mm off. My first unicrown fork was hand-mitred and much further off than that... But forks are quite thick tubing and it's easy to fill a small gap with the welding. Brazing may need a better fit. But it sounds like you won't have an actual gap just very slightly offset blades and a tiny bit more rake.

Usually I get pretty good fits with hand-mitring but unicrown forks are very tricky. For the next one I think I'm going to try and make some kind of fixture and use a hole saw.
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Old 10-25-20, 05:30 AM
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Nice job on the fixturing. I have a similar mill and puzzled over how to make that cut for a while. I ended up hand filing them and that was a pain getting them to match.
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Old 10-25-20, 07:40 AM
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I don't think I can make that cut on my mill, might have to buy a right angle head
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Old 10-25-20, 08:25 AM
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Originally Posted by unterhausen View Post
I don't think I can make that cut on my mill, might have to buy a right angle head
Can you angle the head? I know it's a pain to have to tram it in back to vertical afterward, but if you don't do it often...

Say 45 on the head, and lean the fork jig 45, or whatever combo gets it to fit. Plus/minus the angle due to fork offset, 8 or whatever that is in your design.

Just idly speculating, I don't know anything about your mill of course.

Mark B
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Old 10-25-20, 09:46 AM
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nope, it's a fixed head. Although every time I think about this I realize I could do it in my lathe. A little more setup required.
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Old 10-25-20, 09:55 AM
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After doing a number of main frame and stay miters on the mill I'm pretty comfy with this set up. As mentioned it did rake some trial to figure the most solid method. I have to admit that I have not angled the mill head WRT the table yet. I do think it's slightly off as when end milling a top surface i see one side of the cut having slightly more cutting marks then the other side. I wrecked one of my Mit test indicators a few weeks ago (bummer) and had to bring upstairs my other one to reposition the angle vise and the main vice after this miter was done. What was new was using my electronic tach on the mill for the first time. My low speed is about 197rpm (unloaded). That's about 33% faster then the hole saw guide sheet calls for. Andy
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Old 10-25-20, 07:12 PM
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Tramming a mill is no fun. Especially one that doesn't rotate.
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Old 10-26-20, 03:01 PM
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Last photo for a while. Andy

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