Old 03-20-08, 12:18 PM
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Cassave
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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.

First thing is to braze the seat tube and crankshell.

I've added some stainless cable guides to the crankshell.

Next, miter the downtube/headtube joint...

A fitup with the lower headlug, more lug filing to do before brazing..

.Here's the lower headlug brazed and polished and the toptube mitered and fitted up.......

.And the toptube/seat tube miter fitted up..

As it looks in the jig. Toptube ready for flux.....


Black flux on the headlug since it's stainless.White flux on the seatlug since it's all alloy steel.

The seat lug brazed and cooling off. The flux is now a glassy coating that's starting to crack..........

Last edited by Cassave; 12-02-22 at 11:25 AM.
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