Fork Fixture Nearing Completion

My fork fixture nears completion. I need to pick up some various cap screws, but I'd say it's 90% finished. I'm making a rest for the center post, but I think the piece that I started is too small and I might need to try something else. Hopefully something turns up in the scrap bin. Note the bit of fancy detail on the center post. Just goofing around.



Once this is finished, I'll probably have six hours of shop time left at the Crucible. I'm not sure what I'll make next, but I guess I had better figure it out. I was thinking bottom bracket post for an alignment table, but I don't have enough shop time to complete an entire alignment table. I might consider fabbing a BB mount to this one and creating a rear triangle fixture. Guess I'll have to ponder. It isn't all that pressing because I've decided to buy my shop teacher's small knee mill. I'll only need the labs to build large parts and do the lathe work. Well, until I pick up a lathe.

Onwards, and...Sideways

Frame #1 is a bit out of alignment. Oops. Since I think I know where I went wrong, I decided to start frame #2 before finishing #1. Once I finish the #2 front triangle, I'll work on the rear triangle on #1.

This one is a mix of True Temper tubes and Pacenti lugs for a general-use road bike. Another reason for starting this project is that it appears my office will be moving to where most of us used to work. The lunch rides that I helped found back in '99 (or so) have supposedly grown each year, and I understand Tuesday is still (perhaps more so?) a full-on suffer-fest. It's the one thing I'm looking forward to in the event of a move out of range of my daily bicycle commute.

I want to be able to leave a bike at the office and take the train often, so I'd rather leave this one there set up with some of the older components I've got laying around.

Work in Progress

Just some new photos.

Brazing practice.

The first joint finished, and with the angle dead-on.


Working on the second joint.


The finished front triangle. The top two lugs still need clean-up, but it's together.

More Woodworking

Working with wood to build bicycle frames #3. Tube blocks. I had some scrap oak left over from some other projects, so I gave it a shot. The one on the right was originally a balustrade from Home Despot. You get something like three feet for $3.57. Cut one in half, then clamp the two pieces together and start drilling. Cut off each piece and smooth the edges. I'll probably attach the two pieces with a piece of leather or rubber depending on what I can find, but as is, they are ready for use.

Back to Working With Wood

First wood product - a fork bender. This is my partially completed attempt. Hard maple is wonderful stuff, and should last for quite a few forks. I'm kicking around the idea of fabricating a handle for more leverage and a controlled bend (side to side.) This was a pretty thick piece I found in the scrap bin at a local retailer. I halved it, and glued and screwed it with #8 deck screws. I'm not sure yet if I'll attach it to the plywood. Luckily my neighbor had the 3/8" router bit I needed to cut the groove. Mine was only 1/4".

The glamor side:


Second wood product - paper. This is part of one of my initial attempts to draw out my design. It's actually pretty easy to do, but also a good thing to have a big eraser as it's easy to draw a line wrong.


For the record, the excess headtube above the upper lug has since been erased.

First Silver-Brazing Session

I got a couple of Ritchey crowns for $10 each to use as silver-brazing practice, so practice I did.

The first photo is after soaking the flux off. I'd have spread more flux if this had been for real, but it doesn't appear to have been a problem without. I got some silver on the outside of the crown, but not so much that paint won't cover it up.


Here I've hit the assembly with files and sandpaper strips. It cleans up pretty quickly when you don't burn the shit out of anything.

I've also cleaned up the lower sections where they almost fit the fork legs properly. A little more cleanup and I'll be brazing the legs in place. Then I'll cut it all apart to inspect for proper penetration. I figure I can use this same steerer tube for a bunch of crowns, and the fork tubes for at least two or three crowns just by cutting off the finished parts. I'll also be able to use the fork legs for a couple of dropout practice sessions.

Machine Shop

Some photos of the machine shop at The Crucible where I'm taking a course and a lab (to build my fork fixture):