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. 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://cimg8.ibsrv.net/gimg/bikefor...31bc3ff52b.jpg First thing is to braze the seat tube and crankshell. https://cimg2.ibsrv.net/gimg/bikefor...fb9b6cc2da.jpg I've added some stainless cable guides to the crankshell. https://cimg7.ibsrv.net/gimg/bikefor...79c746a0f7.jpg Next, miter the downtube/headtube joint... https://cimg0.ibsrv.net/gimg/bikefor...8d9a6e7725.jpg A fitup with the lower headlug, more lug filing to do before brazing.. https://cimg9.ibsrv.net/gimg/bikefor...81ee9625cc.jpg .Here's the lower headlug brazed and polished and the toptube mitered and fitted up....... https://cimg4.ibsrv.net/gimg/bikefor...77e7f5f50d.jpg .And the toptube/seat tube miter fitted up.. https://cimg2.ibsrv.net/gimg/bikefor...a9cd52e4a1.jpg As it looks in the jig. Toptube ready for flux..... https://cimg4.ibsrv.net/gimg/bikefor...9dcd8245e1.jpg https://cimg5.ibsrv.net/gimg/bikefor...eeeee304d6.jpg Black flux on the headlug since it's stainless.White flux on the seatlug since it's all alloy steel. https://cimg7.ibsrv.net/gimg/bikefor...2127483dd7.jpg The seat lug brazed and cooling off. The flux is now a glassy coating that's starting to crack.......... |
Moving on..............
https://cimg6.ibsrv.net/gimg/bikefor...5ee9b9c8dd.jpg Upper head lug brazed and the flux washed off, ready to file the lug shoreline. https://cimg8.ibsrv.net/gimg/bikefor...8e7c75519f.jpg The front of the main triangle. Lower head lug polished, upper head filed and almost ready to polish. https://cimg9.ibsrv.net/gimg/bikefor...4e612999e3.jpg The main triangle, brazed. Head and seat tubes not yet trimmed. https://cimg0.ibsrv.net/gimg/bikefor...da172ff638.jpg I'll build the fork next. Prepping the crown. |
Wow.... Great work, and thanks for documenting!
and what are your prices? :D |
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.) |
Originally Posted by prendrefeu
(Post 6374312)
Wow.... Great work, and thanks for documenting!
and what are your prices? :D |
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. |
wow,really cool,please keep showing the pictures/process .
|
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.) Special tools? Not much. Homemade fixtures and fork blade bending tool (more pics coming). |
Thank you. That is an amazing process...
|
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? |
Originally Posted by Cassave
(Post 6374326)
Thanks, but not for hire.
|
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? easy. |
Wow....thanks Steve....very very cool...and extremely interesting!!!
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Right, so BF maintenance/frame ogling party @ Steve's!!!!
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How/where/when did you learn this stuff?
|
Best thread ever.
|
NICE!!!
:beer: |
Originally Posted by gr@sshopper
(Post 6374605)
Right, so BF maintenance/frame ogling party @ Steve's!!!!
|
Originally Posted by gr@sshopper
(Post 6374613)
How/where/when did you learn this stuff?
Like pancakes, the first one's never so good. |
great pics!!!
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PINK :D
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Beautiful Steve.
. |
Originally Posted by alicestrong
(Post 6374998)
PINK :D
NOT PINK. |
Originally Posted by Cassave
(Post 6374413)
That is literally the toughest decision I ever make with these things, the rest is
easy. |
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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