Titanium is softer than steel, so there is no problem regarding tool wear.

As far as bikes go, you're wrong. You can't use a standard facing tool on a Ti BB shell, for instance.

I hate when that happens!

I'm avoiding a chore, so instead I'll post some more fun Ti pics:

5' 9"
Thanks for the suggestion. I've been looking at Ti frame failures and think I'm not likely to get a used frame. Besides, I would like to re-use as many of the existing components as possible. I'm thinking of looking into a new steel frame with compatible dimensions. But at this point, I'm not rushing into anything. I still have an aluminum hard-tail mountain bike, ironically older than my Airborne and a veteran of a lot of miles including the Ore-to-Shore Mountain Bike Epic, that's not cracked, a nice old steel 10-speed and a couple folding bikes. These will keep me on two wheels while I think about the Airborne's fate.

Heh... yeah, I've been looking at those, and it pretty much cured me of the desire to buy a used Ti frame.

Dave does great work. We had him build a titanium tandem for us. Spectacular bike! Give him a call.

Maybe it's superstition but framebuilders don't use Ti tools on Steel or vice versa. Wear is part of it. I think the alloys used in bike making are harder than steels or at least wear tools more. I think there is also contamination of materials. You don't want steel embedded in Ti. I'm saying this based on what I have seen others with more experience than I, do; not based on study or training. Having machined brass and cast iron, I can say they wear drill bits and other tools pretty fast for something that is pretty soft.

No, FBs use steel cutting tools on Ti all the time. Reamers, facers, taps, hole saws etc. They do need to be extra-sharp though, and if you have the luxury of a custom grind, you want an edge with more rake even though it leaves the tip less supported, you need it it cut and not rub. The flexibility of Ti is part of the problem, a seat tube for example can "flex out of the way" as a reamer blade goes by, just rubbing not making a chip. Then it springs back and you haven't actually accomplished anything but wear on the reamer.

The cutter resharpener we used knew how to shape the cutting teeth for Ti.

There is no contamination issue that I know of. Any place that's going to get welded on is well cleaned before welding. I'd worry more about the cutting oil that any transfer of steel onto the Ti. Anyway some strong Ti alloys have a little Fe in them (on purpose), it's not a dangerous contaminant.

I made a request for an estimate, and I'm waiting for a response.

Well, it's a sample size of one but Bill was worried Max would get mad at him for using his Ti cutters on my steel frame. Maybe he was being dramatic.

Oh that I can believe. By "Ti cutters" he means cutters made of steel that are for use on Ti frames. With that sharper rake on the cutting edges, less support for the cutting point, faster wear when used on steel. So definitely keep your "Ti cutters" sharp and away from steel.