The actually fitted Frogmouth MkII

Another quick and dirty update;

Tonight's effort was to blend in the dropouts to the tubes as you can see below, however over the weekend I also modded the jig a bit as I was not happy with how square the dropouts were being held. Doing this also meant that the dropout spacing and centering is bang on now.

Also I just remembered that all this time I have neglected to tell you all about the tubeset that this work of art is being made from. It is all Thron OS tubing, which is a reasonably light, double butted, mid range tubeset that seemed to be the best compromise between weight and robustness. I have found a few references to how well suited it is for the amateur framebuilder due to its slightly better heat resistance, so it seemed the best bet. Time will tell I guess, but assuming that my welding will stand up to the job, then I am hoping the tubes will stand up to the immensity of Pogward that will be pounding it on a daily basis...

The Frogmouth MkII

The dropouts took quite a long time to get made, this is probably because I paid very little actual money to get them done, so this restrained me from ringing on a daily basis and chivvying things along... And this did not matter as it happens, because I have not been in anything like good enough form to do anything about it even if I had them to mess about with. The reason is that I had a serious bout of man flu. Usually in these circumstances I get about as much sympathy as one of the cats does when it has puked on the floor, but as my temperature peaked at 39.5 degrees I could point out that it probably wasn't psychosomatic, and that a wet flannel applied to the forehead just might help alleviate the hallucinations...

It took a full week before my consciousness felt like my body was something that it might think about inhabiting again, and today was the first day in a week and a half that I actually felt well enough to spend some time in the garage...

But to start, before I fell ill I did actually finish the fork jig;

And today I found myself contemplating this;

I had the basic shape machined out, but I still needed to drill and tap the axle adjustment and rack/guard threads. The trusty Grayson and it's plethora of attachments came to my aid;

I had to take all that very carefully as the steel was pretty hard and I was totally paranoid about breaking off a drill or a tap, fortunately things went swimmingly if a little slowly.

Once all that was done I gave the seat and chainstay tabs a bit of a tweak to align them to the tubes;

By which time I was pretty much shattered and had to come in for some tea and a drop of some very fine local beer...

Next job is to make the seat stays and chain stays fit the frogmouths. I have been wondering what to do with the top of the seat stays, I am deeply in love with the stays on this Sizemore;

But a straight copy of this would not exactly be stamping my mark of originality would it? I have a nebulous plan forming in the back of my mind as to what this could be, but we shall see in the fullness of time.

Die MIFA fahrrad, und mehr Fahrradgabel jig

It has been 3 weeks since my last post, amazing how time gets out of hand. I have not been completely idle, but there has been sickness, drunkenness, coldness and laziness to distract from the main event..

One of the more useful distractions has been this thing, which I got as a freebie along with the Gazelle. It has been languishing in bits in my garage, but I thought I had better put it together and see what the story was, and was pleasantly surprised with what resulted;

It is German and probably from the late 40's/early 50's. Hard to tell as there is not much info out there. Actually there probably is and I should clarify my position here; after 4 minutes of googling, not much info turned up. I imagine speaking German might help in this search though. It has some interesting features - square taper cranks for a start, and a sweet clampless attachment for the coaster brake arm. The tyres say 28 x 1.75, but english 28" tyres do not fit, so I assume it has 28"/700c or some deeply strange European variation thereof. The original German made tyres were still in basically functional condition, so I left them on. It also required a 24mm seatpost, so I had to make one to suit as this was missing. Making this has taught me no end of interesting stuff about my lathe and the auto feed....mostly that engaging the fast and slow feeds at the same time is a bad idea, and how to replace shear pins in the drive for the auto feed..... oops.

The Mifa was way too small for me so I have since sold it to one of the tweed boys, hopefully it will give good service.

And onto the framebuilding. A very nice man called Shaun lent me the Paterek DVD's, which made for some hours of fascinating watching. The main result of this was half a day spent die grinding all the lugs to give the correct clearance to the tubes, and a much clearer idea of what to do and when to do it during the brazing process.

Now, a couple of weeks ago the fork jig fairy visited me in my sleep and pointed out that quite a few weeks had passed since I had received the fork jig, and that there was little sign of me actually using it to braze forks with, and (very nicely) asked for it back so he could use it to sort out the backlog of forks he had to build. He made some quite valid points, so I obligingly handed it back. I then got to thinking how nice it would be to have a fork jig of my very own, and then I got to thinking about how sweet it would be if it were part of the frame jig itself.

So today I spent some quality time with the Grayson and ended up with this;

Now I just need to spend a few more hours sorting out the axle attachment, which I will try to make adjustable so that other fork geometries can be built as well...

One of the reasons for slow progress has been the new dropouts. I decided to make these out of 4130 chromoly, and after a wee bit of investigation I found that P20 tool steel is a subtype type of 4130. This is a good thing because P20 is a very common material used in injection moulding tools, and in the course of my work I have quite a lot to do with this sort of thing, and indeed I know many toolrooms that have stacks of it lying round. After some discussions with my favourite machine shop I decided that it would be best to get them to CNC the dropouts for me, because they would then be exactly right first time... and these should be ready on Monday, I can make then make final prep for brazing. I am probably going to hire a gas plant over the weekend, so I would like to get everything ready and do it in one big hit.

Actually building this thing is getting scarily close...

Dropout fun

The great ebb and flow of shedweek has turned in my favour this last couple of weeks, the details of which will remain sketchy for fear of reprisals, but in short it involved my loving wife getting her way regarding the outside tiles currently being replaced by the insurance company, and yours truly paying a not inconsiderable amount of money to achieve tile satisfaction. Money well spent, as the look I get as I slink out the garage is significantly less worrying...

Anyway, this was the state of play a week or so ago, with all of the main tubes mitered in and looking pretty shmick I must say;

Now a while ago I mentioned some custom dropouts getting laser profiled, and these have mostly been the focus of attention this week - apart from a short evening mitering the chainstays into the bottom bracket.

This is what they looked like when I picked them up;

Now at this point I had the brilliant idea of using my lathe as a milling machine to cut away the excess steel on the faces, and that surely some form of compound slide attached to a vise, and then attached to the slide of the lathe would be functional, if a little awkward. The only immediately available thing (ie accessible from the comfort of my computer at 9.23pm on a Sunday night) was this thing on TM with a online price tag of $60. 'Gosh that is cheap' I thought to myself, 'how bad could it really be?' As it turns out the answer to that question is; 'Really, really bad'. So bad in fact, that it turned out to be not only laughably poorly made, but actually impossible to use...

Now using my crude illustration above as a visual stimulus, imagine the top slide being wound backwards and forwards (and feeling disturbingly crunchy while this is happening). Then imagine if you will this backwards and forwards movement causing, by way of a pretty significant interference, the two highlighted nuts to rotate. The more astute amongst you will realise that those two nuts are the locknuts for the slide adjustment, and that for these to rotate by way of moving the cross slide is in fact a wrongness that is so fundamentally wrong it is difficult to find expression for it.

I should have known really, I took the punt on a hydraulically adjustable work bench from the same company once for an assembly jig I was making, imagine our surprise when it turned up and the working surface had a built in drainage drop of 50mm across 600mm of table, but only in one corner....obviously the lesson learnt had dulled over the years and the prime cause had decided to refresh things for me.

So anyway, I then went to a real engineering supplier to try and find something better. After describing my experiences and what I wanted to achieve to the very helpful man, he stifled his mirth and said I should really talk to Sam. Sam was a small man with a rather impressive grey beard who had just arrived in the shop and was waiting patiently to give me his personal opinion of Topmaq, which was not very complimentary much to my surprise.

It turns out that Sam has a superbly equipped home workshop plus many interesting things to look at, including sweet vintage AJS and Matchless motorbikes. So for a couple of boxes of bourbon and coke Sam gave me free reign of his machinery, and the milling machine in particular got a fair bit of use, so I ended up with this;

I then spent this afternoon with files and a dremel to get to this state of affairs;

Clearly there is a bit more to do there, but you get the idea...

In other news, I have purchased two new 28" rims from Dave, and have got the Gazelle hubs nickel plated. I (or Dave) just need to figure the correct spoke lengths and I will build those boys up pronto.

The Gazelle better be bloody grateful is all I can say.

Framejig Ahoy, and bonus Gazelle of Doom...

Mmmmm, Minitec

Now to make it look like that thing up there on the laptop...

Sweet. This is already one brazillion times better than the steel jig effort, stiff as a schoolboy with his first stick mag.

Now to  justify the massive expense of that lathe, this will account for one one half of a percent I would guess;

And that is pretty much where it sits right now, having well and truly used up any spousal goodwill I may have scraped together this week... this is mostly because the Gazelle finally arrived and I spend an extraordinary amount of time getting it to the rideable stage, but still nowhere near finished;

The pics do not do justice to the sheer size or ridiculous rake this thing has.

Everything was against me on this thing, every bolt was rusted up or broken off, and the sweet drum brake wheels are going to need re rimming which is why it has a spare set of 28"s on it for now. The rims actually turned out to be 700c, not the end of the world as I had a set of 700x45 tyres lying around. I thought I would chuck them on despite the poor condition of the rims, just to get it up and running, however one went bang before I even got it onto the bike...

The 700c rims are because it was actually built in 1977, so is a really quite irritating mix of old school design and newish school parts, ie the cotter crank axle was a Thompson type with pressed in shells. Of course I managed to smash one of the cones trying to remove one of the crankarms, rendering the entire crank useless. I then had to machine down a threaded bottom bracket shell and press the whole thing in. It worked well, but what a rigmarole.

On the positive side, the drum brakes were in good condition once cleaned up, and the Sturmey Archer 3 Speed was in perfect condition. A stripdown, clean and reassembly was all that was required there.

To ride it is very spacious and comfortable, and with a set of guards and various other accoutrements it will serve me well as my future Tweed Steed.

Machinery time

Today I have reached a major milestone in this project, and in fact a major milestone in my life, for I have purchased my very own lathe, and what a beauty she is;

I have wanted a lathe forever, but it is only due to the sale of my beloved Fiat X1/9 that I have had the space and the funds to achieve this.

According to my research the lathe is at least 70 years old and so achieves several of my other goals in life; to be old, grey and shagged. I am pretty sure it would not satisfy the needs of my new hero, but to a man of simple tastes and limited skills (me), it will do just fine. I will use this to make bits for my frame jig, and probably a few actual frame bits as well.

I also bought this massive beast as well;

I can probably start an antipodean branch of the British Science Museum soon at this rate. Actually I have been to the Science Museum a couple of times, and there has been a quite irritating tendency towards whizz bang interactive computer displays, obviously in an effort to allow modern children to utilise their 20 second attention span and still learn something. I cannot abide this nonsense, give me a vintage wool baling machine in a dusty glass case any day, I can drool over that crap for hours. Clearly I am in my element here.

So on the actual frame building front I have laid out the frame geometry on my workbench so I can check the angles, and started mitering the tubes. I have discovered that this is so far a relatively simple task as long as you take your time, although I have yet to miter both ends of one tube so there is plenty of scope and time for me to bollox it up.

Laid out to check I have all the bits right;

This one was simply a fantasy exercise, so I can make the bicycle equivalent of vroom vroom noises, a quiet hour passed gazing at this, the wide vistas of my imagination taking me effortlessly over high mountain passes... it was only the growing patch of drool on my chest that snapped me out of it;

And finally at the bottom left is my very first mitered joint, exciting stuff I know.

So this week the focus will be on getting jiggy with it, I am gagging let me tell you.