Monday, January 31, 2011

Here is the first stainless steel head badge that I had laser cut.  I laid it on Zimmys head tube to give perspective and a little contrast.  I only spent a few minutes forming and brushing it.  When formed, the cut edges flare a bit so I need to find some very hard steel that won't dent and allow the flaring  like the S3 I just used. After a bike ride I will work on Devo badge some more and apply the Ninkasi decals to Zimmys frame.

Sunday, January 30, 2011

 No plans for the day, so I decided to go ahead and clearcoat the frame.  Came out very good considering I'm painting in a garage.  I don't plug holes and threads because I always like to chase them any way just to ensure they are clean.  I'll let it cure a couple of days prior to installing the headbage and final assembly.  I'm heading out to Jeds factory tomorrow to pick up some stainless headbadges he had laser cut for me.  Cool.

Friday, January 28, 2011

I thought I would start on Devos head badge tonight.  I slit a 30mm tube and opened it up to 36mm I.D. and squared it off.  I'll brush finish it the same as his down tube and bond the Lion of Bohemia to it then add the CERNITZ logo below it in HFV blue.  And finally clear coat the whole thing.  Awfully heavy.
After clear coating the exposed steel, I had to post this pic.  The clear coat dramatically brought out the colors and deepened the steel.  My printer ran out of ink so I was unable to make the decals.  Tomorrow or Monday.
Did the final sand, seal and base coat.  I like it.  While it's flashing off, I will clear coat the decals and then the bare metal for protection.  Possibly tomorrow I can apply the decal and final clear coat the frame on Monday.  I like to let the decals set up 24 hours to ensure all the moisture is gone.

Tuesday, January 25, 2011

Exercising my time management skills, I went ahead and applied the blue since it required less time than the brown.  I anticipate shooting the brown on Friday and clear coat Friday or Saturday. 
The HFV orange is on and you can see the brushed metal panel that will have the HFV blue logo on it.  The blue will be the last color applied and I have a doctors appointment so I don't know if I will get to the Barton brown today.  I am assuming that Devo wants 1inch stripes on the seat and down tubes.  They need to be that big to have enough presence on the brown.

Monday, January 24, 2011

The frame is primed and ready to glaze the pin holes that showed up during glass beading.
Back from glass bead and sanding the down tube to achieve an appearance finish.  By the way, Devin drew the paint scheme layout.  Time to prime.
I don't know why it is rotated, it isn't in the picture file.  Any
way its paint day if I can get a booth reservation for glass bead. I will call them as soon as they open.  I'm not sure what I will do about a head badge logo.  I'm supposed to be having a stainless steel prototype being laser cut, but I haven't talked to the fellow in the last few days.  I also have the same design out for bid at a different shop and a completely different design at yet another shop.  We will see.

Wednesday, January 19, 2011

Well, no turning back now.  As a component of my "light" lugged frame, I wanted to use an S3 head tube.  One of the factors that contributes to its light weight is its .8mm wall thickness which results in the O.D.  being under size for the lugs. So I cut about .030 out of the lug diameters and brazed them back together.  They fit nice and snug now.  A lot of work for one ounce on these beautiful Llewellyen XL lugs.

Tuesday, January 18, 2011

Minus the 57 Chevy Sea Foam green, these will be Devos colors along with the brushed steel panel on the down tube.  Half Fast Velo, Mule, and Root Beer, not bad.  Lemme know if any changes Devo.

Monday, January 17, 2011

Devs frame is pretty much complete.  Brazed in the seatstay bridge this morning.  Then after a great bike ride, I chased and faced the bottom bracket, cut, reamed and honed the seat tube, and finished the  head tube.  This week, I'll finish all the fillets in anticipation of glass beading on Monday.
I've decided to pull the trigger on my lugged road bike.  I already have it finished in BikeCad, so I'll start the full size drawing probably in the morning.  This frame will set the
 bar for lightness and might even break.  But it will be fun.
 Also, I have received a deposit for what has been named the Robocrosser.

Saturday, January 15, 2011

Here's a couple of shots on how the seat tube junction is progressing.  I like to finish it before I put in the seatstay bridge so I have the extra room for the filing and sanding.  The plan is to finish up all the brazing
 this Monday and then finesse the the fillets for a week.  Then I will glass bead and prime next Monday.  Of course we have to finalize the paint scheme and head badge.

Wednesday, January 12, 2011

 I went to braze the cable stays on and noticed the ugly casting marks, so I filed them off.  Probably wouldn't be noticed, but I couldn't live with them.

Devin and I are kicking some ideas around for his headbadge.  My brother turned me on to this fellow, Milan, in the Czech Republic and he sent me these Bohemian lions.
Maybe solder one of them on to a headbadge sized piece of copper, brass, or who knows what.  Should look good.

Tuesday, January 11, 2011

Devos new seatstays came in today so I thought I would put some time in on them even though it's freezing in the garage with out my infrared heat lamp.  So I dug out the heater we use for cross season and fired it up.  This stay is 95% mitered and will give Devo about 11mm side clearance with the wheel all the way forward in the drop outs and about 15mm in the center. Should be plenty of room for his 2.5 tires.  We need to start planning out the paint scheme now.

Friday, January 7, 2011

Scary shot, eh?  I was so focused on the larger diameter of the 2.5, 29" tire That I didn't provide sufficient seatstay side clearance.  It was only 5mm and Devo needs 10mm.  I will order some straight stays this morning and custom bend them to fit this application.  The 26" MTB stays were just too short in the center section.  The only 29" specific seatstays I can find are the Columbus and they are too long.  I have looked at some of the best local builders 29r's and will use some of their experience in designing Devos.

Wednesday, January 5, 2011

With the exception of the seatstay bridge, the frame is complete through braze.  It now weighs 4lbs. 2oz. Once the bridge is put in and the seat and head tubes are cut to size, etc. the finished weight with the dropouts will be 4lbs. 1 oz.  Very close to what we were shooting for. Oh yea, sorry for another blurry pic.

Tuesday, January 4, 2011

Both seatstays have been cut and mitered and are ready to be silver brazed.  After I align the chainstays in all dimensions, I put in the rear wheel to verify alignment.  Now I will braze in the left seatstay, then check and realign as necessary.  After that I will braze in the right seatstay.

Saturday, January 1, 2011

I was asked about possible interference between the fork and the down tube.  With out the head set there is ample clearance. Add the additional 13mm from the CK and it will be be even better. Love that sloping crown on the fork.  I've been working hard today on designing my personal road frame to replace the soulless carbon one I'm currently riding.  Devo is going to be proud.