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My first TIG frame, a city bike

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    #16
    Originally posted by JPLabs View Post
    A rack, great. I need to make one too, like this month, and am also hesitant to do so in aluminum. For aluminum, mostly I've welded 1/8" plate. Lots of coupons, a few good ones, and then a seat bucket for my homebuilt car. But not so much in small detail work, and nowhere near the serious practice you are devoting yourself towards. Usually, for things like a bike rack, I use cro-moly tube and I have some in 1/4 and 1/2" now. Weld or Tig braze. Both my aluminum Ibera racks have fatigued and broken so I need a tougher rack. I think I'll do steel, but I look forward to seeing what you do there, and what I may learn by watching.
    I have one more day of not being allowed to use my left hand (dog bite, doctor's orders) so I will extract info on welding aluminum from YouTube videos even though it sounds like steel > aluminum for rack toughness. I will make a thread on welding aluminum in this forum subsection.

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      #17
      Even though I have no money, I ordered many more parts for this pedal power city bike.

      Water bottle cages: http://www.bikeman.com/WC4206.html
      Chain tensioner: http://www.bikeman.com/CH8899.html
      Stem: http://www.bikeman.com/SM4158.html
      3/4" rise handlebar: http://www.bikeman.com/HB6840.html
      Rear hub: http://www.bikeman.com/HU5883.html
      Front hub: https://paulcomp.com/shop/components/boost-disk-fhub/ (Black, 32h)
      Freewheel: http://www.bikeman.com/WIND-FWENO16.html

      This bike has an ISO (old school) freewheel. I like 1.375" X 24 tpi freewheels because I love White Industries freewheels and I like to be able to interchange as many bike parts as possible between my bikes.

      I am using the same brakes, water bottle cages, stem, handlebars, grips, pedals, chain tensioner, headset, grips and mirrors that I have on all my bikes, not to mention the same front hub bearings, BB bearings, freewheel and BB spacers, chain, chainring bolts, saddle, headset spacers, trunk bag and panniers.

      The powder coat color (Black Magic https://www.powderbuythepound.com/black-magic.html) is also the same, so one color of touch up paint (ordered from the powder coating shop, minimum order 6 spray cans and not cheap) is used for all bikes and powder coated parts.

      I also bought black aluminum rims for 700 X 40C (40-622) (same as 27" X 1.5") tires. Like I said, I am going to try Tannus tires because flat tires tick me off.

      Front and rear wheels are both 32h with 14 gauge spokes in the very common three cross pattern.
      Last edited by commuter ebikes; 07-11-2018, 09:06 AM.

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        #18
        I spent most of the day building up this bike today. Here it is almost done:

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          #19
          It rides really nicely. This became my favorite bike within the first few minutes of the maiden voyage.

          I will use this bike to commute to work on rainy days. Now I am hoping for rain.

          I took detailed pictures of the build. I guess I will post them here.

          Here is the powder coated frame. I used Frame Saver. Some kids riding bikes in the neighborhood saw me outside spraying in the Frame Saver & I showed them my shop.

          Click image for larger version  Name:	IMG_3587.JPG Views:	1 Size:	2.37 MB ID:	74208
          Last edited by commuter ebikes; 09-20-2018, 10:54 PM.

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            #20
            I installed the seatpost and saddle first in order to clamp the frame in the repair stand. I put white lithium grease on the seatpost in order to prevent binding.

            Click image for larger version  Name:	IMG_3599.JPG Views:	1 Size:	2.61 MB ID:	74210
            Last edited by commuter ebikes; 09-20-2018, 10:55 PM.

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              #21
              The first thing I did was make sure that the rear wheel (I had both wheels ready) fit straight in the frame. I was happy that it went in straight.

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                #22
                Here it is with the rear wheel in:

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                  #23
                  I was using a Chris King headset. I took a picture, failing to notice that the crown race (stainless base plate) was missing (!).

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                    #24
                    Here is the headset installation tool with the Chris King inserts:

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                      #25
                      Here is the headset being installed:

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                        #26
                        Here are the headset bearing cups in the head tube.

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                          #27
                          At this point, I was horrified to notice that the crown race was not in the package. I called my supplier in Maine, but they were closed due to the coast to coast time difference. I called Chris King and they said that they would mail me one for free, but that I should call around because a LBS might have one.

                          I was very happy that the third LBS that I called had the part. O happy day! This is the $20 crown race:

                          Click image for larger version  Name:	IMG_36333.JPG Views:	1 Size:	347.9 KB ID:	74225
                          Last edited by commuter ebikes; 09-20-2018, 10:58 PM.

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                            #28
                            Here is the crown race installation tool with the crown race, Chris King adapter and BFH.

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                              #29
                              Here is a closeup of where the action will take place:

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                                #30
                                I put foam on the floor so I wouldn't damage the fork:

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