Work and Fun

Since Melissae has come home from Germany, I haven't really posted much. But I have started picking up the work pace. It's kind of odd that I seem to get more done with her around than when she's gone. Between picking up the extra slack at home, and not having my moral boosting buddy, I haven't really got much to say for the three months that she's been gone.

But Matt's frame is coming right along. And lately, some good progress has been made. But that also didn't stop me from being dragged by the good guys of Team Seagal out to the Thursday night dirt crit series at Castlewood State Park. Man was that a blast. That was despite half of the B's crashing each other (or themselves) out in an adrenaline powered orgy, clawing at dirt and grass, on their ultimate quest for a slightly lower place number in their second tier class standings of local notoriety. I managed to keep the rubber side down in my personal quest for checking out and having as much fun as possible in the local scene. And it really was a great scene. A ton of people out to have a good time, mixed with free food, beer, riders of young and old, bikes ranging from mtn tandems, kids bikes, and bmx's, to full carbon race machines, finely tuned for local dominance. It really was great to get out, ride, and see people of all sorts sharing what it is to ride a bike through the woods.

But enough fun, back to work:

Main frame is all mitered and ready to rock.

Seat stays shaped, and with caps brazed on top.

Second section of seat stays brazed and cleaned.

Showing how the segmented seat stays will come together with the wishbone. This is the idea that Matt helped me come up with. I really like this look, and may have to re-visit it in the future.

Days of Hard Work, To Save Time

Well, that's the idea anyhow. The last three days that I've spent frame building (which translates into the last two weeks), I haven't built much in the ways of frames. Instead, I've built what I hope will save me a great amount of time in the future: A front derailleur braze-on mount jig. That is, I built a thing that will allow me to (in a matter of minutes) braze on a front derailleur braze-on tab to a road bike seat tube.

Before I braze the front triangle of the frame together, I like to do the braze-ons. That way, any distortion made to the tubing happens before the frame is together. Because any distortion after the frame is together could cause misalignment, and add further stress preload to the tubes. But this makes it really hard to get the braze-ons exactly where I want them, as there is no other part of the frame to reference. Many braze-ons can be off by a millimeter or two, and not really affect anything. Just think of the travesty that would occur if your water bottle mounts were another millimeter further for you to reach whilst riding. Not to say that I don't spend entirely too much time making sure they're exactly where I want them. But if they were a tick higher or lower on the tube, I wouldn't exactly scrap the whole project. But if your fancy front derailleur needs to be one or two millimeters higher so you won't shift it straight into your chainrings, but can't because the mount is just a hair off... well that pretty much sucks. So normally, I spend about a half of a day measuring, re-measuring, checking, re-measuring, tacking, checking, and brazing to make sure that darn thing is exactly where I need it.

But now, once I make the BB miter on the seat tube, I hook up my modified bottom bracket shell into my frame jig, bolt on the derailleur braze-on tab, load up the seat tube (held in place on the top by my frame jig, and on the bottom by the braze-on tab itself and another bit of steel welded to the faux BB), and braze away. It should be dead on to both handle compact road cranks, and the typical 39-53 combo. If a customer does want to make it custom to handle something outside that range, I can use only one of the two tab mounting bolts, and go higher or lower. But no matter where I put it, the tab mounts square and flush to the seat tube, and only a few minutes to set up! Oh man, I can't even tell you how excited this makes me. And no, I won't build you one! (maybe one day when I have a full machine shop, and I can make something like this a little quicker)

Three days of hard work, and this odd little thing is what I ended up with.

A mitered out bit of extra down tube helps hold the seat tube in parallel.

Here it is in action, mounted up in the frame jig, just after I used it for the first time.

And after all that, there it is. Right exactly where I wanted it, and square to the BB shell. (when it is in there)

Then, and now...

Ok, so I've been gone for some time now. Well, not literally. Over the winter, I was working on getting my motorcycle kit up and running. Most of it went pretty smoothly. But I quickly learned that I am not an electrician. All the mechanical bits seemed to be a logical combination of my background of working on my own cars, along with working on bicycles of all trades. But when it came to the wiring, I had never really learned much past the couple weeks my high school physics class talked about circuits and V=IR. But I can now say after re-wiring it a few times, and one electrical fire, I know a ton more than I did before. The bike is now running, and I just have to jump through some legal hoops to get it legal.

My wife, Melissae (finally) graduated her PHD in chemistry at Washington University of St. Louis in the spring. So the lead up to that got life a little crazy. After that, we got her ready and packed for a three month internship in Germany. During which time, we moved a buddy and co-worker in to help me pay the rent while Melissae is gone. This is going a long way, as not too long after the internship is over, she has gotten into a science writing program in Santa Cruz for a year. You can read about her adventures at her blog:

Weltanschauung

After a bunch of life hitting all at once, I'm back and ready to tear into some frames. Thanks to those of you hanging in there with me and my delayed posts/builds. First up, is Matt's commuter bike, with clearance for some cyclocross tires. Kind of a go anywhere, from home to work, to going for a dirt ride on the katy trail. It will be a mix of lugs and a fillet brazed BB junction to allow me to direct the chain stays however I need to, to best gain chainring/tire clearance. The first two miters are made, and I spent half the day re-shaping the top tube / head tube lug. Nothing overly fancy or ornate, but I like how it turned out.

As always, more pictures on my Flickr site

Oh The Places You'll Go... (long post)

So instead of another post talking about how I've been super busy, life's hectic, I haven't done as much frame building, but stay tuned.... I thought I'd spend a little time talking about product differentiation. It's never a bad thing for a company (or individual) to come up with new ideas, push limits and boundaries, and try to keep things moving forward. And with every progression comes a time when that person or business can say "Hey, check this out! It's cooler and better than the other guys!" But when the differentiation is either just plain different to be different, or possibly even comes with a downside, then why bother? That is, unless we reallyneed to be different so badly, that it's worth paying more to have a thing of less quality. Before I get to some examples, don't get me wrong here. I'll be the first to admit that it's cool having things that set me apart from all the other 25-30 year old, middle class, caucasian, males out there. But not when doing so sets me apart in a negative way.

I was looking through the wonderful eye candy of the 2010 NAHBS pictures, and came across some gorgeous examples of skill, creativity, ingenuity, and of course, many ways of differentiating one builders frames from another's. There is the obvious material differences, paint differences, component selection, and tube shaping. But there is also differences of welding in extra tubes or bits to either enhance the strength, ride, or even nothing but aesthetics. However, I also saw a few examples of doing something negative, just to get attention. I borrowed a few pictures from Dirt Rag's coverage of the event to illustrate what I feel to be a negative direction for frame building as a whole.

I don't mean to call anyone out in particular, or start a rapper style war. But when I see things like this seat tube cutout, leaving just a hair of material left, I have to wonder about the intentions. Strength/stiffness/weight, this is definitely worse off. Aesthetics, well that's a bit objective, but if I were to sacrifice that much for looks, I'd at least want the curve of the cutout to match up with the curve of the wheel. Would having a plated 29er with track bike clearances set you appart? Absolutely. In a good way?.... well, I'm sure you could find someone out there that would think this is cool.

Again, I fully appreciate the fact that from 20 feet away, most steel frames start to look pretty similar. And I'm all for something neat to set you apart. Hell, even if it adds a few grams, as long as it really makes you happy. But sometimes paint matching and shape matching the "power bulge" of your Rock Shox fork on your head tube, and adding what appear to be cable rubbing bars, so the cables rub a different part of your expensive paint, doesn't seem to be a progression and argument to buy custom.

Working in the bike industry, I get to see plenty of examples of details that set one companies frames apart from each other, but add nothing to the actual performance/weight/functionality of the bike, and sometimes end up making one of those aspects worse. I understand the cutthroat nature of corporate production, and appreciate being able to stay competitive. And hell, at this point, I'd expect a corporation to do change things on a frame without truly understanding the consequences that change could have on either riding or working on that particular bike. It's not like everyone in a business that large rides and works on their own bikes. But when a small frame builder - with hopefully a passion for bicycles and the desire to balance the drawbacks of a design to the minimum - starts doing things like this, I'm personally disappointed.

Everyone has their own flavors, and that's what makes getting a custom frame awesome. You can match up with someone of similar taste/personality, and get exactly what YOU want. But what I'm afraid of, is that the NAHBS (while doing a great service of bringing custom frame building to the people/media) is, or could go in the direction of creating even more of an incentive for a builder to do something outlandish, just to get some attention at their tiny booth in the sea of like minded competitors.

As beautiful as some of these things are, compromises are being made. And there's nothing wrong with that, just so long as you know and appreciate them. I just hope that the circus aspect of this sort of thing doesn't push the builders out there that take it upon themselves to design a well fitting, well riding, and functional piece of artwork, out to the fringe of the already niche market they are a part of. I try to keep in mind the origin of a custom hand built frame, when it was appreciated as the best sort of frame one could own. I also try to keep in mind how much a custom steel frame has improved over the years, with new steel blends, heat treatments, fillers and fluxes, and even modern components that help the frame become what could still be a high performance machine. The progression is there, however hidden it may become, beneath the marketing hype, and lets face it, the need for product differentiation.

(Thanks to Dirt Rag for the pictures. Hopefully my lack of making money off of them keeps this from violating some sort of copyright)

No, I'm not dead...

I'm still working out the final details of Matt's big tire'd commuter/cross frame and fork. I've got all the shiny bits here already, and should be pretty awesome. More on that soon. I've also been trying to look up what all I have to go through to get a business license, insurance, and maybe even hook up a dealership status for some components to offer complete bikes when the time comes.

I've also had a winter project that is just about done. I've been trying to wrap that up, so it doesn't distract me from frame building once I start filing. It's a 200cc motorcycle kit from Kikker 5150. I've wanted a motorcycle since I was a kid. And now that I'm getting old and married, I figure I better get one before life gets any crazier, or I have to be a responsible dad or something. I figured I'd give this one a try, hoping the building would teach me a thing or two about motorcycles, plus they're pretty affordable.

All in all, I've definitely learned a bunch trying to work out all the kinks and problems. I figure it's about on the moto level of a mid to upper priced wallymart bike. However, if you strip them down, and re-build them from the ground up, doing every step correctly (not how local high-school Joe built it), and even replaced a few parts (that won't even work right no matter how much "tuning" you give them), you won't end up with a great bike. But if you do the work yourself, it will still be affordable, and it will be good enough to get you around for a while. I'll just have to keep in mind that the riding experience will most likely be better with a "real" motorcycle.

I've already sorted out all the mechanical issues keeping me from giving her a first ride, but a major electrical issue is keeping me from getting any spark. I was really hoping that the electrical would go together smoothly, because that's one thing I really don't know enough about. But hopefully I'll sort it out soon. And either way, the next frame will be coming together shortly.

(As it came, once I unpacked it. The handlebars and a pile of other parts are not in this picture.)

Sparkle Sparkle

Man, it's been a while. But I've finally got Eddie's 650b hardtail and suspension corrected segmented fork done, painted, reamed, faced, chased, frame saved, stickered, and delivered. Definitely a learning experience, this frame and fork turned out pretty well. New things that I've learned include S-bend seat stays, chain stay and down tube (or really anywhere) gussets, and working with super tight clearances. All in all, a success!

Eddie went with me to the painter to choose a color, and we both discovered that he does metal flake paint! So on went a two coat "emerald green" that looks unassuming inside or on a cloudy day, but out comes the sun and BAM! She lights up like Oz's Emerald City. I've got some pictures, and even one with a high powered flash to simulate being outside. But really nothing does it justice like seeing it in person on a good day.

Now on to the next project. A commuter styled cyclocross inspired road bike of versatility and awesomeness for Matt. Just a couple more details to iron out, and then building begins! So untill I've got some build shots to tease you with, here are some of Eddie's bike. (more on my flickr site)


(With the flash to try to simulate the sun hitting the flakes... trust me, it looks way better in person)

Staying Busy + Good Book

Sorry I haven't posted in a good while. While the swine flue did knock me out pretty good for a few weeks, lately I've just been busy catching up with life. I do think (even though this is a bit different for my blog) I should mention a book that I managed to read while sick. Shop Craft as Soulcraft was one of those books (for me) that seemed to put into words, things and ideas that I've been mulling over since people first asked me as a kid "What do you want to do when you grow up?" While not exactly my words, it seemed to express the deeper reasons that I've come to appreciate while deciding to get into bicycle repair and frame building, as opposed to following my Economics degree or Philosophy minor. Not that this book is for everyone, but I feel that there are a handfull of good ideas that even office dwellers can appreciate.

But not to get too caught up in a good book, I have managed to get some more work done on Eddie's frame. I went a bit out of order on this one, and chaced/faced the B.B. shell. That way, I could install some cranks, and check the exact tire/chainring clearance that I've fretted about since first drawing up the blueprint for this frame. There wasn't much room for error when threading the drive side chainstay between the tire and chainring. (only a couple millimeters on each side) So it was a great relief to see everything go from blueprint to finalized function. I've also got both seatstays with custom S-bends fitted and mitered. Just a couple braze-ons, weld the stays, make a seat stay bridge, and some finishing work, and she's getting close to paint.




More pictures here.