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Rack build for Routens

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Rack build for Routens

Old 09-15-19, 12:50 PM
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Rack build for Routens

@merziac suggested I make a thread about building the front and rear racks for a JP Routens frame. I am moving the frame on to a new forum member but wanted to build the racks before shipping it off.

The frame is a camping frame made of 531ST. It was built to take panniers front and rear and a handlebar bag. It has 3 sets of rack mounts along the seatstays on the rear, and a pair of fender eyelets. On the front there are fender eyelets and mid-fork and bottom-of-the-fork braze-ons for low riders. Front and rear have braze-on mounts for centerpulls. I've seen similar Routens' frames with the racks positioned low to the ground. I will try to emulate the design.

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Old 09-15-19, 12:59 PM
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Excellent, can't wait to see this.
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Old 09-15-19, 01:01 PM
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I'm planning on using 3/8" OD seamless stainless steel tubing for both racks. I want to keep the racks relatively lightweight while still being able to carry panniers, so I am opting for 0.035" wall thickness tubing. I'll be using my TIG welder for tacking and then the joining will be done via silver brazing using Cycle Design Fillet Pro rod and flux, to keep the look traditional.

The first design choice to tackle was how the racks will be mounted. With 3/8" OD, 0.035" wall thickness tubing, the ID of my tubing is 0.305". I found some stainless eye bolts with a 5/16" thread diameter, which is 0.3125", just slightly larger than the ID of my tubing, and with the right sized bore for the M5 bolts used on the frame mounts.

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Old 09-15-19, 01:06 PM
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I decided to start with the rear rack since it is somewhat simpler than the front rack. I'm starting with the horizontal elements of the rack.

I use a Ridgid manual tubing bender for stainless steel to make bends for racks like these. It mounts in a vise and has long levers for making the bends. I made the bends and trimmed the ends to the right dimension to fit around wheel/tire/fender. I then cleaned up the ends, and gave a quick grind to the threads of the eye bolts to allow them to fit snugly into the ends of the tubing. Fluxed and then torched.



Did a bit of clean up but will wait 'til the end to do final finishing.

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Old 09-15-19, 01:42 PM
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I decided to put a mount for a rear light on the bottom corner of the rack. I have some nice M6 threaded stainless spacers. Put a radius into one of them with a rat tail to fit against the rack tubing, tacked with the TIG welder and then brazed it.





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Old 09-15-19, 01:51 PM
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This is so cool.
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Old 09-15-19, 04:57 PM
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The new owner is going to be very, very happy!
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Old 09-15-19, 06:14 PM
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I cannot wait to see this. Looks like a great start so far. Thanks for taking the time to make a thread. I love fabrication pictures.
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Old 09-15-19, 06:27 PM
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Mad Skills Sir, very cool thanks for sharing
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Old 09-15-19, 07:32 PM
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I am continually amazed by the various skills displayed by our members.

Kudos to you and thanks for sharing this with us.
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Old 09-15-19, 10:39 PM
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Absolutely fascinating post. Great details. Step by step with photos.

Subscribed.
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Old 09-16-19, 01:39 AM
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Originally Posted by The Thin Man View Post
Absolutely fascinating post. Great details. Step by step with photos.

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+1

Beautiful frame too
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Old 09-16-19, 09:53 AM
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Much respect for your skills, and for your willingness to employ them so ably for a bike on its way out the door.
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Old 09-16-19, 01:15 PM
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Originally Posted by due ruote View Post
Much respect for your skills, and for your willingness to employ them so ably for a bike on its way out the door.
And it will be so much more complete with them.
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Old 09-16-19, 02:31 PM
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Originally Posted by TenGrainBread View Post
The first design choice to tackle was how the racks will be mounted. With 3/8" OD, 0.035" wall thickness tubing, the ID of my tubing is 0.305". I found some stainless eye bolts with a 5/16" thread diameter, which is 0.3125", just slightly larger than the ID of my tubing, and with the right sized bore for the M5 bolts used on the frame mounts.

Where did you get those eye bolts? Just asking for a friend
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Old 09-16-19, 02:41 PM
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Originally Posted by scarlson View Post
Where did you get those eye bolts? Just asking for a friend
https://www.e-rigging.com/five-sixte...s-eye-tab-bolt

$2.61 a piece. Not super cheap but cheaper than McMaster or a framebuilder supply shop.
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Old 09-16-19, 03:16 PM
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Fantastic, this will be a fun one to watch!
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Old 09-16-19, 03:22 PM
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Originally Posted by TenGrainBread View Post
https://www.e-rigging.com/five-sixte...s-eye-tab-bolt

$2.61 a piece. Not super cheap but cheaper than McMaster or a framebuilder supply shop.
I don't think any framebuilder supply shop sells rack tabs in stainless, do they? I have only seen steel. I'm getting some laser cut.
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Old 09-18-19, 02:25 AM
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Originally Posted by gugie View Post
The new owner is going to be very, very happy!
He sure will be.
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Old 09-18-19, 11:06 PM
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Originally Posted by unterhausen View Post
I don't think any framebuilder supply shop sells rack tabs in stainless, do they? I have only seen steel. I'm getting some laser cut.
Mitch Pryor had some on his website for sale awhile back, but stopped doing them. Then there was the Paradise Fire, and now he appears to be out of the framebuilding gig, at least for now.

And I am pretty excited about you making some!
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Old 09-19-19, 09:29 AM
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sorry, I'll order soon. I'm still designing things to get cut, like a crank clearance gauge for compact and grx cranks.
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Old 09-19-19, 10:49 PM
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Originally Posted by unterhausen View Post
sorry, I'll order soon. I'm still designing things to get cut, like a crank clearance gauge for compact and grx cranks.
You gots the dims from the Compass gauge? I've got one of those, could measure for you if it helps.
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Old 09-28-19, 04:21 PM
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Originally Posted by TenGrainBread View Post
I decided to put a mount for a rear light on the bottom corner of the rack. I have some nice M6 threaded stainless spacers. Put a radius into one of them with a rat tail to fit against the rack tubing, tacked with the TIG welder and then brazed it.





How's this going?
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Old 09-28-19, 04:29 PM
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Was on a work trip but back in the shop today to finish the rear rack. Been spending a lot of time thinking about the front. I want a modular design where the low riders can quickly be removed and installed. I have an idea in mind.
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Old 09-28-19, 04:45 PM
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Originally Posted by TenGrainBread View Post
Was on a work trip but back in the shop today to finish the rear rack. Been spending a lot of time thinking about the front. I want a modular design where the low riders can quickly be removed and installed. I have an idea in mind.
Excellent, wish I were closer to you and could have some built for this,

Merz RR150 built in 78 but no racks, Original owner went with blackburns on the cross country trip he had it built for.

As my go to commuter/short tourer it would be great to have similar spec customs for it although if I ever actually stepped up I would like them to have Merz style attachments, which might be a stretch.








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