Weekend Update

Well this week was quiet as our 9 to 5 jobs got the best of us. Andrew's road frame is at the painter's, Mo's is at the powder coat, and Cody has been working with Bill and Mary on designs for our next two builds. Bill design calls for a curved top tube, so this week we worked on bending tubes. First, we gave a try with a cheep rolling tubing bender and although it was able to bend the tubes, it also ovalized the tube as was run through the rollers. We used the 1 1/2 inch rollers that came with the bender and I will really need to machine up some 1 1/8 inch rollers to prevent the tube from being flattened. Here is a shot of Mo rolling a bend into the tube.



I have also have another method for bending tubes that I want to try, so we picked up some 3/4 inch plywood and so far have been able to construct the wooded base curve to bend the tubes on. It is three layers thick, with a routed groove in the center for the tube to sit in and is based on a 24 inch radius circle. Here are some construction shots:





We still have to add a base plate to the curve, a strap to hold the tube in place and then we will give it a try. I have some straight gauge 4130 on the way and will take some photos of the bending process with it.

Big props to one of our customers, Jackson Smith, who started the Arizona Trail 300 on Friday on his True Fab 29er and is so far doing well in the race. Here is some links to track his progress:

http://www.topofusion.com/azt/race.php
http://trackleaders.com/aztr
http://www.bikepacking.net/forum/index.php?PHPSESSID=eaed8d9e148db62599f8ba34770f7bb0&topic=753.40

Keep on rolling there Jackson, we all are watching your spot tracker go!!

Weekend Update

While Mo finished the clean up on his road frame, I worked on his fork. First I cut a sleeve for the steerer tube and tack it on.



Then I miter the steerer tube at 6 degrees.



And finally tack on the fork legs which I had mitered earlier in the week.



I then welded the fork legs on and welded caps on the tops of each leg. Here is a shot of the frame and fork. All that is left on the fork is to drill and braze in the brake bolt boss.




We also worked on prepping Travis's frame and all that is left on it is to install the head tube badge.



We should be getting Andrew's frame and fork back from the powder coater tomorrow and then work on prepping it next. This week we plan to try out our new bender and bend some top tubes.

Neopoltian Ice Cream Paint Job

Today our painter dropped off Travis' geared TF hardtail over here at the Hammerhead Shop. I must say it turned out very nice. The cool thing is that he completely left the color combo for his bike in my hands. Its a rare occasion that a customer says....paint it how you'd like! Thus it made for a fun project. Knowing Travis as well as I do it wasn't too hard to choose something I thought he'd like. It doesn't translate at all in the photos the fact that the diamonds are different colors. They are alternating tan and white. My inspiration for this color scheme was Neapolitan ice cream.

Now we have to do final prep on the frame and put the head tube badge on it. I know this may sound cheesy but its really an honor to make frames for Travis. He and his wife now own a total of 3 TF frames and 1.5 forks. :) Travis will get the joke.

Mo's frame done

Yesterday, Mo got all the braze-ons done on his frame. He has a little more clean up on it but it is complete.



Here is a shot of the rear end:



I started work on his fork, which is going to be an interesting project. We are going to go sort of uni-crown / semi-segmented , by welding the fork legs directly to the steerer and then cut and cap them like a segmented fork. I was able to braze the front dropouts on and start mitering the legs.

Mo's Road Frame Welded

Last night I was able to get Mo's seat stays welded on and I think they go well with his choice of chain stays went on the frame.






Today, Mo is going to work on getting all the braze-ons welded on and then we will move on to his fork, a uni-crown road fork that is going to be something new for us to make.

Weekend Update

We made good progress this weekend on Mo's frame. While I welded up the front triangle Mo mitered the chain stays for the dropouts. I then welded the dropouts to the chain stays and then welded the chain stays to the frame.



Mo is going to go with strait seat stays with his straight chain stays, a very traditional look, and we were able to get them mitered up as well.



The plan is to get the seat stays on this week and then add all the braze-ons as well. By next weekend we should have a frame ready for powder and can get started on the fork. I was able to get some machining done this weekend on a fixture for mitering unicrown forks on our lathe. I was able to cut the t-slots in the base plate and will work on the front axle holder and fork blade blocks next week.



I was able to catch the last few hours of Paris Roubaix this morning online and was impressed by Cancellara just motoring away from everyone with 50k to go.

Andrew's Done - next up Mo's Road bike

Quick post from this week's progress: Mo finished all the clean up on Andrew's Frame and Fork and it will go to powder tomorrow.



We are next building a traditional level top tube road bike for Mo. He was able to get the front triangle all mitered up today. I was able to weld the seat tube / bottom bracket junction and then get the front triangle all tacked up.

Wrapping up Andrew's frame and fork

This weekend Mo and I worked on finishing up Andrew's Road frame. On Saturday I mitered up and welded on the seat stays. I also cut and brazed in the rear brake bridge.



Here is a shot of the frame and fork without the braze-ons yet.



Today, Mo brazed in all the cable stops and water bottle braze-ons. All we have it a little more clean up on both the frame and the fork and it is ready to go to the powder coater.



Andrew, please let Cody know your color =).