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-   -   How to build a lugged steel frame, with pics (https://www.bikeforums.net/framebuilders/399311-how-build-lugged-steel-frame-pics.html)

Cassave 03-20-08 12:18 PM

How to build a lugged steel frame, with pics
 
I've had a few people suggest that since I'm building a new frame why not document it in a
thread. So, for those that might be interested here's how a lugged steel frame goes together.
I know some of you have barely or rarely seen lugged steel frames but this is how bikes have been
put together for over a century.

https://vgy.me/PqgZEj.jpg
I'm using a Deddaccia Com12.5 tubeset, Henry James lugs and drops, Everest crankshell
and a full sloping stainless fork crown.
The head lugs and fork tips and drops will be high polish.

https://vgy.me/duMHnJ.jpg
First thing is to braze the seat tube and crankshell. I've added some stainless
cable guides to the crankshell.

https://vgy.me/fnU4e8.jpg
Next, miter the downtube/headtube joint...

https://vgy.me/AVxtdi.jpg
A fitup with the lower headlug, more lug filing to do before brazing...

https://vgy.me/28SAVX.jpg
Here's the lower headlug brazed and polished and the toptube mitered and
fitted up.........

https://vgy.me/3CVl4b.jpg
And the toptube/seat tube miter fitted up...

https://vgy.me/G9WEc5.jpg
As it looks in the jig. Toptube ready for flux.........

https://vgy.me/MNrPkR.jpg
Black flux on the headlug since it's stainless..

https://vgy.me/cMsHQg.jpg
White flux on the seatlug since it's all alloy steel...

https://vgy.me/Tx6vRF.jpg
The seat lug brazed and cooling off. The flux is now a glassy coating that's
starting to crack..........

Cassave 03-20-08 12:23 PM

Moving on...............

https://vgy.me/yO6gfb.jpg
Upper head lug brazed and the flux washed off, ready to file the lug shoreline.

https://vgy.me/Ta1bTo.jpg
The front of the main triangle. Lower head lug polished, upper head lug
filed and almost ready to polish.....

https://vgy.me/4TND1W.jpg
The main triangle, brazed. Head and seat tubes not yet trimmed.

https://vgy.me/FDmMUc.jpg
I'll build the fork next. Prepping the crown.

prendrefeu 03-20-08 12:27 PM

Wow.... Great work, and thanks for documenting!

and what are your prices? :D

Brian Sorrell 03-20-08 12:28 PM

Very nice pics. Can you talk about your experience leading up to this project -- e.g., other metalworking skills that you have, special tools, have you built bicycle frames before (I assume that you have), etc.

(For my money: lugged steel is as beautiful as a bicycle frame gets.)

Cassave 03-20-08 12:29 PM

Quote:

Originally Posted by prendrefeu (Post 6374312)
Wow.... Great work, and thanks for documenting!

and what are your prices? :D

Thanks, but not for hire.

roadfix 03-20-08 12:31 PM

Is that the 53 you're putting together for me? So far so good!

Thanks for posting, this is very interesting. I wish I had the tools and the skills to do this.

HAMMER MAN 03-20-08 12:33 PM

wow,really cool,please keep showing the pictures/process .

Cassave 03-20-08 12:35 PM

Quote:

Originally Posted by Brian Sorrell (Post 6374317)
Very nice pics. Can you talk about your experience leading up to this project -- e.g., other metalworking skills that you have, special tools, have you built bicycle frames before (I assume that you have), etc.

(For my money: lugged steel is as beautiful as a bicycle frame gets.)

This is frame 60 something. I built the first one about 1975.

Special tools? Not much. Homemade fixtures and fork blade
bending tool (more pics coming).

alicestrong 03-20-08 12:38 PM

Thank you. That is an amazing process...

VanceMac 03-20-08 12:40 PM

I'm not sure I understand... is this the mold, over which you will lay the carbon fiber?

But seriously, can't wait to see it. Color scheme?

WhiteCarbonDude 03-20-08 12:42 PM

Quote:

Originally Posted by Cassave (Post 6374326)
Thanks, but not for hire.

Not fair!

Cassave 03-20-08 12:43 PM

Quote:

Originally Posted by VanceMac (Post 6374391)
I'm not sure I understand... is this the mold, over which you will lay the carbon fiber?

But seriously, can't wait to see it. Color scheme?

That is literally the toughest decision I ever make with these things, the rest is
easy.

herbm 03-20-08 12:53 PM

Wow....thanks Steve....very very cool...and extremely interesting!!!

[email protected] 03-20-08 01:11 PM

Right, so BF maintenance/frame ogling party @ Steve's!!!!

[email protected] 03-20-08 01:12 PM

How/where/when did you learn this stuff?

GP 03-20-08 01:40 PM

Best thread ever.

BluesDawg 03-20-08 01:52 PM

NICE!!!
:beer:

Cassave 03-20-08 02:06 PM

Quote:

Originally Posted by [email protected] (Post 6374605)
Right, so BF maintenance/frame ogling party @ Steve's!!!!

So very very wrong. :eek:

Cassave 03-20-08 02:07 PM

Quote:

Originally Posted by [email protected] (Post 6374613)
How/where/when did you learn this stuff?

Just dove in (a long time ago).
Like pancakes, the first one's never so good.

jsigone 03-20-08 02:08 PM

great pics!!!

alicestrong 03-20-08 02:12 PM

PINK :D

thomson 03-20-08 02:14 PM

Beautiful Steve.
.

Cassave 03-20-08 02:14 PM

Quote:

Originally Posted by alicestrong (Post 6374998)
PINK :D


NOT PINK.

WhiteCarbonDude 03-20-08 02:16 PM

Quote:

Originally Posted by Cassave (Post 6374413)
That is literally the toughest decision I ever make with these things, the rest is
easy.

I would go with copper plate.

alicestrong 03-20-08 02:27 PM

Quote:

Originally Posted by Cassave (Post 6375017)
NOT PINK.




Now how did I guess that you might say that? :D

But seriously, thank you. I know when I first read here that you built bikes I was very curious but I never did make it over to the Framebuilders subforum so thanks again for putting this together...

Now when they get that hemp based frame material perfected...:p


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