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Terry’s SS silver brazed kick ass road frame

Terry’s SS silver brazed kick ass road frame

bicycle, brazed, columbus tubing, custom built bicycle frame, custom built hard tail street frame, custom frame, custom tips, hand built bicycle frame, hand built custom bicyles, lugged, machinery, primate frame, tools, Welded, Wet Sprayed, workshop0 comments

this is Terry’s stainless tubed frame .

Terry came to me looking to get a titanium tubed road frame but as I explained to him , I have been playing around with TI for a little bit now just getting to know the medium and welding up small pieces to teach my self how to work the metal but I was not confident enough with the material to offer it out as a frame just yet. To this end I had been reading up on the new SS tube sets that where out there and I soon found out that the specks of the SS tubes where on par and in some cases better than titanium and they can be silver brazed so I would be able to work with the welding medium that i specialize in and if all the data sheets ran true have a very light and lively rust free frame at the end of the things.

After talking Terry threw his options and drawing up his frame in cad we came up with the final design which was a pretty easy task as he had been fitted up by Steve hog from Cycle fit and there was only a few mechanical changes to the design that need to be made.

I was a little apprehensive with this tube set as I knew from the specks that it was very very hard and SS is a tricky material to weld with it behave very differently when heated, and being on the very expensive side of the tubing price chart I was defiantly steeping lightly with this one.

the first problem  I encountered was mitering the tubes, I have some very high end silver brand machined cutters That I use for very light and aero shaped tubes they are dead true and very expensive, With SS you have to use a lot of coolant and a slower cutting speed to stop excessive heat build up that will destroy the cutter and work harden the tubes making then even harder to cut and work .With this in mind I spent a lot of time setting up my mill to get everything running correctly, the first cut gave me an idea of how hard this material  is .The stuff is unbelievable each cut was done with a prayer and held breathe but I got thru them all till I was on the last cut. I was all set up with a brand new cutter all going well till it broke the surface and there was a very loud bang  not the sound I wanted hear and I figured that was the end of that tube. after stopping the machine and dropping the table to inspect the damage I was very surprised to see the tube un harmed , I’m thinking score lucky break there But as I cleaned the cutter to my horror I see 3 teeth missing from my brand new $360 cutter. I was having a bit of trouble coming to terms with this, the tube I was cutting has a wall section of .7 of a mm the cutter has a wall section of 2.5mm and is hardened and ground! I knew the tubes where hard but this blew me away.

Though I was bummed about the broken teeth on the cutter one of the main reasons I chose these cutters is that they can be reground with new teeth so I thought sera sera ill just have to get it re cut but on closer inspection i found a hair-line crack running the full length of the cutter “F#%@’ $360 gone in under a min welcome to the wonderful world of  high temper tubes.

After switching to another cutter I very carefully finished cutting the tube .

With the tube set cut and dressed it was onto the next challenge the welding.

Thin walled high temper tubes are always  a challenge especially when they are silver brazed  . Controlling the heat between the different wall section tubes yet making sure that there is enough heat for a solid molecular bond between the material’s  whilst working up  the fillet and making sure not to burn of the silver flux has taken me a lot of years to master, through into this mix the very quick heat transfer of the SS tubes and I was kept on my toes gluing this  frame together.

Terry wanted a frame that was classic but not to old school l so I went for a good mix of fittings to this end giving the frame the small touches that really give a hand-built bike its individual character.

the last thing was a custom SS logo done it Terry’s initials but in the end I was concerned that the amount of heat that I would have to put into the frame to fit the badge was going to upset the welds and there was a real chance of it distorting the thin-walled tubes and putting the frame  out the alignment.

Well the frame is of at star enamelers weighting for its turn in the line up to get sprayed, Terry is still working out his color scheme but at last count it was looking like a hot red with wight  panel , what ever way the color ends up this will be a very hot looking bike.

I’ll put up some shots of the frame and bike when it’s all done .

Stay upright Tarn.

There’s Pink and then there’s PINK

There’s Pink and then there’s PINK

bicycle, brazed, columbus tubing, costom scooter, custom forks, custom tips, lugged, machinery, primate frame, tig bike frame set up, tools, Welded, Wet Sprayed, workshop6 comments

My new toy is all complete.

Well when you ask peter from stat enamelers to do some thing in hot pink that is certainly what you get .

I spent all night putting this evil little beautiful together and gave it its first run today, very sweet I can see my self having a good time with this toy.

The deck is a slab of 3mm carbon fiber sheet . The brake is a section of high tensile stainless steel tube cut and shaped to fit works a treat. titanium handle bar. oury lock on grips . Brooklyn machine works bar end caps. syncros  threaded head set. Luksa 100mm 85a wheels. ceramic bones red bearings. hand cut carbon head tube badge.

I will be taking her down to the skate park to see what all the young monkeys are on about and to try not to deck my self to hard.

play hard and stay up right

Tarn..

The devil’s play thing

The devil’s play thing

bicycle, brazed, columbus tubing, costom scooter, custom built hard tail street frame, custom forks, lugged, machinery, tig bike frame set up, tools, Welded, Wet Sprayed, workshop4 comments

If satan had a son and satans son rode a scooter this would have to be satans sons scooter!!

My latest crazy build is almost ready.

About 5 years ago I started to see a lot of kids on razor scooters in the skate parks. This use to give me the shits (and it still does when parents use the park as some sort of  pre school and let there very young kids loose with scooters  unsupervised while they talk shit and drink coffee in the corner!!) I was always thinking get a skate board or a bike and stop pissing around on that half ass attempt at both. That was till I saw a 10-year-old kid bust a 2m back flip out of the bowl whilst doing a double 360 and landing it!  suddenly I had a whole new respect for these monkeys they where throwing down some big shit, but they were doing it on the old folding neck  piece of crap scooters and  they where defiantly not designed for that sort of  abuse.

So I started toying with the idea of  building  a hard-core scooter, but i didn’t really  think  there was much chance of selling such a thing so it went on the back burner.

Any way jump to the present and I was starting to see heaps of kids with what looked like some pretty serious scooters rolling the streets.

Gone were the break neck fold up decks these things where all one piece and looked pretty trick , and the bar was a cool segmented hard-core looking thing. The forks where by far the coolest  looking bit of kit all CNC’d super trick looking pieces.

Well this was my Q to re visit the idea of a hard-core scooter again. After a bit of home work I saw just how far things had moved on, and I’m kicking my self a bit  for not getting in there sooner, you snooze you loose .

Looking out there I could see that there was still room for something a bit different (this is always my excuse to justify building my self a new toy!). So one quiet day at work it was out with auto cad and start to create on-screen what was floating around in my head.

A bit of  R&D and I had the geo and length sorted out, then It was a matter of trying to work out how I was going to jig it all up? At first I tried  to use my frame jig but that turned out not to be a workable option so it was on to my alignment table with clamps and spaces to get every thing running true and straight. A few hours of fine tuning and I had it set up to tack, tacked and welded and it was all looking sweet. next was the forks I played with the idea of doing a CNC’d set but then I thought why not try for a lugged set of forks after much deliberating and playing around with different crowns  I settled on the ones you see in the pictures. I must admit I really enjoyed building this little toy as it started to take shape I kept getting more and more ideas about how i wanted it to look or what would look cool on it, to this end I remembered I had some tapered plugs I had bought a while back from Paragon machine works and I thought they would look trick on the forks and the rear of the deck. I would pull them out and lay them up on the rig then think no leave them off and put them away only to pull them out again, indecision..

finally I thought why not and filled them out and dry fit them and im glad I did they looked sweet.

next I had to turn up the axle tips and braze them in on the forks and tig them on the deck, with the deck and forks finished I turned my attention to the stem and bars.

I wanted to use a set of titanium handle bars that I had so I machined out a tube to fit the bars and welded it to a very nice tange prestige down tube  that I had in my kit the end result is a very light super strong bar stem combo.

all in all it turned out very well and she is of to get sprayed this week. I wont give away what color she will be but lets say Barby would be proud .

For the rest of the build I have a cool set of  Luksa 100mm wheels and I’m getting a solid carbon fiber plate that I will be making into the top deck, I also have a funky brake system worked out but I’m not sure if I’m going to be running it yet might just stick to the old sneaker  stopper.

well I’ll put up some shots when I get her back from the painters and have her all built up and rolling .

so if your thinking you need something super special or super hard hit me up. I am keen as to whack out some more of these baby’s .

stay upright

Tarn..

Williams Wonderfull 29er

Williams Wonderfull 29er

29er bike, bicycle, brazed, columbus tubing, custom built bicycle frame, custom built hard tail street frame, custom forks, custom frame, custom mtb bicycle frame, custom tips, hand built bicycle frame, hand built custom bicyles, machinery, primate 29er bicycle, Welded, Wet Sprayed, workshop1 comment

Well I must admit to leading a double life for the lead into this story.

I work a full-time job as a theatre technician (basically I run the back stage of the Sydney theatre),  In this job I meet a lot of different  people, we get all sorts come through our venue from total amateur shows to big productions with a lot of big name actors in them.

Truth be told I don’t have much time for most of them they are just part of my job and some of them have egos so large I’m some times surprised they can fit  them selves through the doors  (and we have some big doors at work).

So when the boss told me we where going to have William Hurt with us on stage for out next production I was curious to see what sort of person he was.

Well it turns out that some times in life you meet some one who is truly special. I don’t find many people who I would say that about, but William is defiantly one of them.

Long story short I found William to be extremely open and down to earth and I could see he was not having a great time on the show we where working on so I took upon my self to break up his day with a chat and a laugh when I saw him at work.

I had a feeling that William might have been a bike person but I didn’t want to seem as if I was trying to sell him something as I’m sure he would get hit up by people trying to sell stuff all the time so I just kept out chats away from bikes.

Any way I was on my way to work  listening to the radio and they started talking about the show we where working on  and the DJ started talking about William Hurt and what he had been up to since he arrived here.  Turns out one of the first things he had done was to go and purchase a bike from Tokyo bikes in Surry hills.

So that night at work I asked him about his bike and told him I built frames. He asked to come up and have a look at the work shop I have set up at work (I am very lucky in this regard as my boss is a top bloke and has no problem with me working on bikes if there is nothing happening around the building, so I have a very nice little work shop set up in the theater) luckily I had two frames that had just come back from the painters.

Well after a very short time William was complementing my work and  saying he wanted a bike built, I didn’t really take him seriously at first as he had literally been in the work shop 5 min.  He must have seen what I was thinking so as he turned to me and said “I’m serious I want you to build me a bike” and to reinforce this he came up later to tell me again to seal it with a hand shake.

Well this threw me  into gear as the production was only in town for another 3 weeks.  After talking to William about what sort of bike he was looking for and looking over his body shape I had him sent to Steve Hog at cycle fit to get the full fit up treatment.

Luck was on my side here as Steve is usually 2-3 months booked out, but he had a spot the following Mon, score..

Well over the next few weeks I worked out the spec of the bike with William and as you can see from the photos there was very little spared, this thing is bling as bling .

William went back home and I set to work creating his bike I really wanted this to be something special.

To this end I designed and  had some custom tips cut to fit his frame geo and to house the rohloff  .Then I used a lovely set of Columbus fast back single bend chain stays, I have had them sitting in my tubes for a while as I can’t get them any more I was waiting for a special build to put them into and this was the perfect one.

Then there was the chain ring This is my Karma ring I designed this shape when I was first learning to use auto cad but as it was such a complex pattern I held of getting it cut .Then when I met William I knew he was the perfect candidate for the Karma ring, William is a very spiritual person who practices meditation and holds strong beliefs based around it. my Karma ring is based on an Indian Mandala which is used to focus the meditation practice, perfect for the bike and the man. to this end William asked if I could not put my skull logo on the head badge as he doesn’t like to celebrated death, no problem. Then it was the small details that really finish of the build like in laying the paint in the head tube reinforcement rings and hand painting the ti and soldered spokes (this looks really cool when the wheel is spinning as you get a funky little band of color in the wheel).

After talking through the components and working out what forks we where going with (rock shox Reba RLT TI ) but we had them painted to match the frame with my logo running up the front, sweet

the rest of the build is all the usual high end suspects Thomson/king/salsa/Easton/middleburn/hope/mavic .

This has been a great build for a really nice person and I feel very lucky to have met William and to have had the opportunity to build something for him.

Enjoy your new ride William may she bring you many years of good Karma.

Stay upright Tarn.

the flying wedge almost ready to roll again

20" BMX, brazed, cracked bicycle tube repair, lugged, machinery, primate frame, Welded, Wet Sprayed0 comments

Hear are a couple of shots of a repair that I just got back from the paint shop.

this Is Sean Malvern star flying wedge frame, this repair came to me when I bought out Big John from Cycleundergrounds stock had to track down the owner Sean thru various contacts to check if the repair was still a go ahead, after the job was confirmed it was down to business fixing things.

the first job was to repair the seat rail bridge the original fitting was a flimsy pressed metal affair that had let go so I set to work cutting out a new fitting that sat across the orignal bridge and connected the twin spars across the top all washed in with a good run of brass ,well solid. I then went and laid  some brass on the down tube seat tube joint as it was a bit rough and lastly had to clean up support fin joints again they where a bit rough and a bit light on in some areas.

Next was the flared HT .  it’s all ways a bit of a challange  doing flared HT some can be saved others are just to far gone to be brought back but this time ti all looked good The orignal tube was very thick wall material so I was able to ream out the bottom of the tube to accept thin-walled 1″ head tube section that i brazed  in and then fitted a reinforce ment ring down the bottom to give it some more strength. It all went smoothly and after running the head tube reamer thru it was ready to go of to get a fresh lick of paint.

I went the great oracle of the web to get photos of the color and try to get some shots of the decals. The color was not a problem to find, but getting good shots of the decals was not that easy, to this end Sean came thru and found a set of  decals.

all in all she came out very nice and I look forward to seeing her all built up.

I’ll threw up some shots when she is rolling.

Stay upright Tarn..

Corey’s frame back from the painters

custom forks, custom frame, primate frame, Wet Sprayed0 comments

Corey’s custom track frame back from the painters ready to get packed and shipped.

Corey's frame back from the painters

custom forks, custom frame, primate frame, Wet Sprayed0 comments

Corey’s custom track frame back from the painters ready to get packed and shipped.

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