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Building lugged CX/touring bike

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Building lugged CX/touring bike

Old 06-17-19, 10:09 PM
  #51  
Saul KK
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Bent up a seat stay bridge, and added a boss for fenders.




Nice beefy chainstay bridge brazed in. Also added a Fender boss here.



Here's the jig I made for holding the cantilever bosses in place while brazing.



Fork cantilever bosses all brazed up.



Decided to add some support fins on the rear cantilever cable stop.




All cleaned up.

Last edited by Saul KK; 06-18-19 at 09:24 AM.
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Old 06-17-19, 10:48 PM
  #52  
Saul KK
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Head badge design I came up with. I then cut this out of some thin stainless sheet with a small rotary tool and files.

Silver brazed onto the head tube along with a small brass plate with my initials.



Completed frame minus final clean up and paint


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Old 06-18-19, 07:24 AM
  #53  
unterhausen
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That looks really great, thanks for posting pictures. Your headbadge is nice, understated but attractive. You might have gone a little overboard on the rear brake cable stop though.
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Old 06-18-19, 08:06 AM
  #54  
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Very nice! I like most all of the style and sizzle (although I still dislike straight blades) To Eric's comment about the rear brake cable stop- placing a small hole roughly in the gusset's center would reduce the visual mass. Andy
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Old 06-18-19, 10:30 AM
  #55  
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I was a little worried about the hanger being bent on my travel bike. Going to have to think about it a little more. Although I might just go with a detachable hanger. This one would make it through TSA and baggage handlers just fine, that's for sure.
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Old 06-18-19, 06:53 PM
  #56  
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Thanks, I was pretty happy with how the head badge came out.

Yeah I can see what you mean about the gussets, but I like them as is. I thought about doing holes in them, but didn't want the added visual complication. The bike was actually finished almost a year ago, I've just been slack with updating this thread. Anyway point being, the gussets look a little less visually dominant with the frame built up with all the components.

The rear dropouts are Llewellyn ones from ceeway, and yeah it would take a pretty decent whack to bend the derailleur hanger, it's pretty beefy.
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Old 06-18-19, 10:02 PM
  #57  
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Saul, would you share your rattlecad file? I'm curious about your geometry, especially how you kept a 59 degree bottom lug angle with a 400 mm axle to crown.
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Old 06-19-19, 08:47 AM
  #58  
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Here's a photo of the frame dimensions, I think it should have everything on it you might want to know. Let me know if not.
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Old 06-19-19, 09:06 AM
  #59  
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I don't think most people can see that, so image assist
Attached Images
File Type: jpg
geometry.jpg (342.2 KB, 174 views)
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Old 06-19-19, 09:17 AM
  #60  
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You can click on it and zoom in, or am I missing something?
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Old 06-19-19, 09:25 AM
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Thanks. That's perfect.
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Old 06-19-19, 04:31 PM
  #62  
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any pictures of the bike built up? i really like how it came out, i'd love to see it completed!
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Old 06-20-19, 04:06 AM
  #63  
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Thanks, I keep meaning to get some good photos, but haven't managed yet. Here's some I found on my phone in the meantime.

I also brazed up some racks out of stainless tube. I'll get some photos of those too.
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Old 06-21-19, 04:10 PM
  #64  
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Originally Posted by Saul KK
Thanks, I keep meaning to get some good photos, but haven't managed yet. Here's some I found on my phone in the meantime.

I also brazed up some racks out of stainless tube. I'll get some photos of those too.
that looks like a proper blacksmith shop there.....what is the forge setup?
and very nice bike
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Old 06-24-19, 06:25 PM
  #65  
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There's two forges, a smaller venturi style gas forge, and a larger one for bigger pieces like scrolls.
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Old 07-02-19, 03:54 PM
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Originally Posted by Saul KK
Thanks, I keep meaning to get some good photos, but haven't managed yet. Here's some I found on my phone in the meantime.

I also brazed up some racks out of stainless tube. I'll get some photos of those too.
sorry, i forgot to check back in. your bike came out great! i need racks for a couple of my bikes and when i shop around and see how much the nicer stuff goes for i start to think i'd be better off borrowing my dad's brazing rig and build my own. sure, they might be terrible, but i'd bet they would work ok and i would probably learn some things.

Last edited by t_e_r_r_y; 07-08-19 at 01:17 PM.
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Old 07-03-19, 09:03 AM
  #67  
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terry- Rack making can be an awarding project. Yes you'll learn a bunch. Pretty much all the fabrication skills needed to make a frame are used when making a rack. Andy
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Old 07-04-19, 04:50 AM
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I see why a lot of builders don't like to build racks, and will only sell them with a frame. And the ones that do sell racks charge accordingly. It's not easy unless you are building many racks of the same geometry and have fixturing.
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Old 07-05-19, 11:44 AM
  #69  
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Originally Posted by unterhausen
I see why a lot of builders don't like to build racks, and will only sell them with a frame. And the ones that do sell racks charge accordingly. It's not easy unless you are building many racks of the same geometry and have fixturing.
Lesson learned for sure. My custom rack has so many welds on it. I know it was a lot of effort for sure. I definitely didn’t appreciate how complex they were at first glance on the price range.
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Old 07-07-19, 04:49 AM
  #70  
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Old 07-07-19, 04:58 AM
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To be honest I didn't find the racks too hard, but I went with a relatively simple design. The trickiest part was making the front rack rectangle meet back up in the right place.

I bought one of those $20ish tube benders off ebay, which felt like it was on the verge of breaking every bend, but it held out, and made half decent bends. I reckon you could get away without a bender if you don't mind the tube flattening out a bit more. Just bend it around something round.
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Old 07-07-19, 09:32 AM
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the right size v belt pulley works well
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Old 07-08-19, 01:25 PM
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Originally Posted by Andrew R Stewart
terry- Rack making can be an awarding project. Yes you'll learn a bunch. Pretty much all the fabrication skills needed to make a frame are used when making a rack. Andy
i've done a lot of mig and tig welding and a little bit of brazing, but nothing quite at the detail and precision level of bicycle stuff. i know i have the skill to do it, just none of the experience. i would really love to build my own frame one day, building my own racks would be a good step in that direction i think. saul's build is definitely inspiring!
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