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How to build a lugged steel frame, with pics

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How to build a lugged steel frame, with pics

Old 04-04-08, 12:17 PM
  #76  
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Originally Posted by magicant View Post
Beautiful pics, Steve.

The text however =
Greek to you?
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Old 04-09-08, 09:51 AM
  #77  
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Ok, moving on. Starting to look like a bicycle frame.



The chainstays and chainstay bridge fixtured, fluxed and ready to braze.


Brazed and cleaned, ready to file.


Nice. Done with all the heat in this area so I'll chase the crankshell
threads.....


Here's the bottom bracket tapping tool. Set up with English taps,
left side= right hand thread, right side = left hand thread.


Cleaning the threads of excess brazing alloy.


Threads ready for a bottom bracket, I'll face the ends last, just before
paint.

Now on to the seat stays and brake bridge.......

Last edited by Cassave; 08-29-17 at 10:14 AM.
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Old 04-09-08, 01:11 PM
  #78  
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Clint,
Great posts! So very interesting, and much appreciated.

What do you think about the stainless steel tubesets, like the Columbus XCr tubeset used by Pegoretti for his Responsorium? Do you think this material has utility, and how hard is it to use stainless vs. regular steel tubesets?
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Old 04-09-08, 02:24 PM
  #79  
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Originally Posted by DScott View Post
Clint,
Great posts! So very interesting, and much appreciated.

What do you think about the stainless steel tubesets, like the Columbus XCr tubeset used by Pegoretti for his Responsorium? Do you think this material has utility, and how hard is it to use stainless vs. regular steel tubesets?
As far as I know, the Columbus tubes are made from a Carpenter Steel, 400 series alloy.
It was designed as a forging alloy, not for drawn tubes. The materials are fine to work with,
but a bit tougher on cutters due to the high nickel and chromium levels. Brazing is no problem
with the right fluxes.
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Old 04-09-08, 03:29 PM
  #80  
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I don't have the time nor the skills to do anything close to this, but thank you just the same for a very informative thread.
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Old 04-09-08, 06:35 PM
  #81  
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Originally Posted by Cassave View Post
Ok, moving on. Starting to look like a bicycle frame.
Hi Steve,

This has always looked like a bicycle frame to me -- a very nice bicycle frame.
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Old 04-14-08, 10:04 AM
  #82  
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The work progresses. I finished the rear triangle.
The one spot that framebuilders typically try to make a signature design is
the seat cluster. It's a very low stress location on diamond frames so it offers
a lot of possibilities for variation. The design I prefer is the one here. I've
built several frames with the same very clean modified fastback design.


Fitting up the stays. Some profiling still to be done.


The fairly complex shape that needs to be filed into the top of the seat stays.


Getting there..........


Fluxed and ready to braze.


Brazed and cooling.



There, cleaned, filed and showing the finished brake bridge as well.


Added the front derailleur boss and two pair of bottle bosses as well.

Next, on to the small braze-ons. Cable stops and guides.

Last edited by Cassave; 07-10-17 at 09:56 AM.
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Old 04-14-08, 10:09 AM
  #83  
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Originally Posted by Cassave View Post
Threads ready for a bottom bracket, I'll face the ends last, just before
paint.
I thought facing was best done after painting?
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Old 04-14-08, 10:19 AM
  #84  
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Following progress. Looking good!
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Old 04-14-08, 10:24 AM
  #85  
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just outstanding and the process with the pictures is really super-cool.
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Old 04-14-08, 10:32 AM
  #86  
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This has got to be one of the coolest most worthwhile threads I've ever seen on here.
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Old 04-14-08, 10:39 AM
  #87  
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Originally Posted by Pepper Grinder View Post
I thought facing was best done after painting?
Facing after paint tends to chip the paint on the circumference of the BB shell.
Only the fixed side cup actually interfaces with the end of the BB shell. The non-drive side
cup sits inside the thing with the end of the shell showing.

I just take a razor blade and remove the paint on the end of the fixed side before installing the
bottom bracket.
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Old 04-14-08, 11:19 AM
  #88  
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Are you using one of Henry James' frame jigs?
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Old 04-14-08, 11:23 AM
  #89  
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This is a great thread. Thanks!
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Old 04-14-08, 02:16 PM
  #90  
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Originally Posted by Fat Boy View Post
Are you using one of Henry James' frame jigs?
No. All my tooling is homemade. Most of it's older than
Hank's line of jigs.
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Old 04-14-08, 02:18 PM
  #91  
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Originally Posted by mtblurkr View Post
This is a great thread. Thanks!
My pleasure, glad you like it.
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Old 04-14-08, 07:52 PM
  #92  
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I love that seat cluster, beautiful work.
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Old 04-14-08, 10:53 PM
  #93  
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+1 on the seat cluster. That is beautiful. Can't wait to see the paint scheme. Any thoughts since the last time you commented? Wet or powder? If I remember the lugs are going to be polished right?
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Old 04-15-08, 07:45 AM
  #94  
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Beautiful! My kind of bikey!
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Old 04-15-08, 09:37 AM
  #95  
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Originally Posted by MTBMaven View Post
+1 on the seat cluster. That is beautiful. Can't wait to see the paint scheme. Any thoughts since the last time you commented? Wet or powder? If I remember the lugs are going to be polished right?

Definitely wet (automotive acrylic urethanes with clear coat).
Probably 2 color and yes the head lugs, dropouts and fork crown are polished stainless.

I'll tryout some custom decals using the Pappilio waterslide paper I just found.
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Old 04-16-08, 09:08 AM
  #96  
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C'mon, man...ease up! this is like freakin' torture! Home-made tooling, an original design where allowable (seat cluster), all steel construction, polished stainless lugs, wet pai....
Sorry, I have to go wipe myself now.
But seriously, will there ever be a right price for it??? Please?
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Old 04-16-08, 10:35 AM
  #97  
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Originally Posted by pv0463 View Post
C'mon, man...ease up! this is like freakin' torture! Home-made tooling, an original design where allowable (seat cluster), all steel construction, polished stainless lugs, wet pai....
Sorry, I have to go wipe myself now.
But seriously, will there ever be a right price for it??? Please?
Ah, you never know.

I'll build it up and see how I like it.
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Old 04-16-08, 11:05 AM
  #98  
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Awesome thread. Great pics. Excellent work.

This photo is brilliant!
Originally Posted by Cassave View Post
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Old 04-16-08, 04:19 PM
  #99  
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A few more shots from last evening.........



The brake cable guides brazed to the top tube.


A close up of one, the flux starting to crack as it cools.


And the rear derailleur cable stop (on the bottom of the driveside chainstay.

Next come some homemade parts; chain hanger pin, shifter cable stops
and stainless wire bottle cages (similar to Nitto). Stay tuned...

Last edited by Cassave; 07-10-17 at 09:59 AM.
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Old 04-16-08, 04:27 PM
  #100  
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Is it wrong that I'm almost as equally impressed that you're making your own cages as I am about the frame itself?
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