Building a Bicycle Frame with Dave Yates – Day 2

2012 April 14
by Chris Vernon

Day 1Day 2Day 3Day 4Day 5

Lots of jobs on day two, some big, some small, most escaped the camera:

  • Finalise dimensions
  • Round off spikes from lugs
  • Mitre top tube – braze onto head tube
  • Bend fork blades
  • File dropouts smooth
  • Cut fork blades to length
  • Lathe crown race
  • Drill air holes in fork blade
  • Drill (and recess) hole for brake in fork crown
  • Braze fork blades into crown
  • Mitre top of down tube
  • Cut out small bridge from bottom bracket (between chainstay lugs)
Top tube

Here is the top tube mitred to fit the head tube.

Top tube and head tube

The fit is pretty good!

Fork crown race

The fork crown race has to be cut to exactly the right diameter for the headset. We used a lathe for extra precision.

Top tube brazed to head tube

Here's the top tube brazed to the head tube.

Brazing the forks

Here the fork blades are being brazed into the crown.

By the end of day two I have a few sub-assemblies. The top tube and head tube, the seat tube and bottom bracket, the forks are pretty much done and dropouts are on the chain stays. On day three it should come together to form a bicycle shaped object.

Day 1Day 2Day 3Day 4Day 5

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