ftw industries

FOUND MYSELF

2011-10-18T02:44:00.000-07:00

After losing my account information for this blog, I had almost given up hope. Just a little while ago, while walking the dog I suddenly remembered the information!

I have decided to create a blog that can be moved to my domain (frankthewelder.com) on Wordpress. Here is another temporary address while I learn to use the new format.

Here is the new blog address. http://frankthewelder.wordpress.com/

Now, if I could only find my 18X1/2" flexy ruler with the 1/100 scale and my winter booties.

New steel bike project.. 29" wheels AM free-ridey type of machine.

cool progress

2011-09-21T02:55:00.001-07:00

Sorry I don't have any pics posted today. The last month (my performance) was sort of lame. Between the rain and the usual daily calamities it was just blah on certain days. The riding has been good which can often "save the day".

Actually, I am sure I got a bunch of stuff done and had a blast in the process or I may have broken a bunch of end mills and mangled several miles of tubing. I think we can agree that this month, like all months is a mix of good and bad.

I am happy to report that the road builders have done a great job fixing the washed out roads in our area. The bridges are still broken or gone though.

The colors have started to change so I will add some outdoor images in with the shop stuff. I have been taking pics of shop stuff so don't fret. If you want to come to Vermont to see the fall colors, please do. We are still a bit messed up but are ready to receive guests.

"Like I was saying..."

2011-09-13T15:13:00.000-07:00

Sometime when we are hanging out, I will explain the significance of that phrase. It really means a lot to me. In a funny way.

I have been working on a few projects that require a new bend radius. For those of you that haven't bent metal tubing before, it's a bit like when you were a kid and while playing would grab a rope or whatever held in someones hand and "spooled it up" by spinning around, pulling the other end toward you. The trick with the metal tubing is getting a firm grip on the tube and having a "track" to guide it into a smooth "loop".

If you are trying to roll a small loop with thin tubing it could buckle. Sometimes the "grip" is lost in the end in my "hand" and other times the tube just rips in half. One cure is to use a larger bend radius. To add an element of excitement (ya, a real nail biter here) I use a mandrel which is basically a ball that is at the end of a rode that extends inside the tube. The ball is they held by the rod right at the "moment" of the bend.(the point where the bend happens)

To make the die I need, I need a BIG chunk of metal. I could use aluminum or steel for this project but for the aluminum version I need a 12"X2"X8" piece.

I was digging around a bit in the shop and found some halves of old dies that were missing some features I would need. The odd part is only one half on the die fit the tube, the other was for 1" tube.

So, my lathe wasn't big enough so Nolan let me use his. I had to flip the jaws but whatever, it was progress. Keep in mind I am driving around with this 60 lbs chuck of metal in my car. Crazy.

Here is the part "chucked up".

So the next part is to try to match the radius of the die to the radius of the tube. (not the tube bend, the actual radius of the actual tube)
I ground a form tool for the job. I didn't use a comparator.

Once I had that worked out, I notched the die to weld the tube clamp to hold the tube while I pulled it around.

I finished matching up the surfaces so that I wouldn't damage the tubes. Here is a pic of the die ready to go.

I finally got the first sample through and it was perfect!! Worth all the effort for sure. This not only matches the Original Yet bend but it's a lot stronger than a tight radius as used in a fork leg.

today's update

2011-09-06T02:40:00.000-07:00

Hi, I hope you are all doing well. I haven't been getting much work done this past week with all the rain damage. I personally didn't have any troubles thankfully but it's been stressful none-the-less. I am not sure how another night of rain worked with all the new river banks the work crews put in last week.

I have a full plate this week for sure. I have a snow bike to finish (I failed on the fork bends and waited a bit for more materials) and some other small repair jobs that have really been at the shop for a bit too long.

I did manage to slip out for a couple of good rides between the thunder storms.

Good luck to those in the other areas around the world. There seems to be plenty of trouble areas.

More chances to ride/Leef clothing.

2011-08-21T04:02:00.000-07:00

The weather and daylight seem to have aligned themselves more this summer than anyone in the past. I like plenty of rain, which we get but thankfully there has been plenty of chances to do what we like best. RIDE.

There is a new outdoor clothing designer fabricator here in town which I think is great. The company is called LEEF and is a outdoor lifestyle producer with a nice edgy look and an eye on performance. I wish LEEF good luck and prosperity.

I welded up Andrew's Magneto road frame. It's built to his own specifications with careful attention to tube specification. We ended up bringing in the head angle just a bit to match the current available forks. He also requested a front-derailleur braze on, so that was also done.

This image should take you to the full set. Thanks for lookin'

a fork

2011-08-17T02:38:00.000-07:00

here is a fork I made on my upgraded tooling. This was a lot more fun than usual.

The news has been pretty alarming lately. I just go to work and try to forget about it. How are you doing?

Fork fixture

2011-08-11T02:31:00.000-07:00

I have to apologize. I spent most of the month walking around all day staring at the sun, drinking pure corn syrup. I think I lost a bit of weight to boot!

Now that I have returned to action, I am pleased with my progress. I have a bunch of fork jobs stacked up that I am well into at this point.

I have had this fixture for a while but it needed a bunch of work. It also maxed out at 45mm of offset which always made me nervous for some reason. Since this photo was taken, I added some devices to hold the folk legs during the tacking process.

I also have a some help at the shop. A friend, David is helping me get the place a bit better organized.

Greetings.

2011-08-09T01:40:00.000-07:00

Hi, thanks for reminding me about the blog. I have been busy on a number of projects in the past couple of months. I have also been riding quite a bit.

I am close to completing a couple (like today) a up-grade on my fork fixture. With all the new steerer sizes and the long 29 forks the device had become obsolete. I also make a fork raking machine for regular steel road forks.

My machinist friend Neil was supposed to help me out on this but he wasn't able to get to it. I just need to bolt it together and BINGO

I am also getting some help in the shop as my friend David is visiting for a while. David used to race BMX quite a bit and we are going to get a machine going for him soon. A combo touring and BMX racer. Not your typical bike or fellow.

Speaking on BMX, Kev sent my suspect device back along with it were some part that belonged to my Jalapeno BMX. So, for the next couple of posts, we are going to feature some BMX bikes both new and old.

First on the list is my Jalapeno pro cruiser. I built this frame in about 1992 or so and raced it quite a bit in the 90's. I also raced a bit more recently in perhaps 1998 or so in CT. It's built from 6061 T-6 and utilizes 7/8" square tube stays that are very stiff. I think the frame is under 5 lbs (more likely around 4 ).

The wheels are comprised of Campagnolo pista (track) hubs, Sun CR20 rims (usa made) bullseye cranks, Brand X stem, Jalapeno fork and aluminum bars. I used to run around 97" gear if I remember correctly. What a bike.

Bikes this week.

2011-07-12T01:55:00.000-07:00

A few jobs are wrapping up this week. The 26" free-ride hardtail has been fun. Lots of custom-ness. I am also making a snow bike but I am waiting for a response to a question I had.

I also have Lee's bike finishing up. I need to come up with a good way to remove flux from brazed frames. There is no water in the building (at least until it rains).

I am really glad I get to do this for a living. Not just making bikes, but living in small town and just being small. I am sure this place is like any other but to me it's perfect. It's a drag that there is sop few jobs but the odd thing is, no-one seems to be looking for work.

When School was letting out for the summer, Chris potter grabbed all the tomato and pepper starts that were left in the garden and brought them around for folks to have for their own. I took about 100 plants but found that most of my friends already started theirs. I finally managed to give most away but I did keep some Roma and sweet 100's to grow in front on the shop. Chris is also the local undertaker, plows my driveway and sings in a band on Saturday nights. He is really good too!

Fail

2011-07-11T03:29:00.002-07:00

get tangled when a code didn't work.. back to retail with you guys.

good morning.

2011-07-08T02:54:00.000-07:00

Today, I am here not to talk about what I make, but what I want. No, don't expect a list of demands. I am a happy guy and don't need much.

What I do like to do is use good products when I ride or work and form solid relationships that last a long time. I also like to really examine things I use and try to get the most out of them. No, I don't mean destroy them. I mean use stuff than works and lasts.

I have applied to a promotion group to get samples of quality goods. Stuff I can put to work on the bikes you ride and the body that makes them.

Since I don't have a fancy title or team of fork lift drivers to back my play, I decided to make this post and direct the person that reviews my application to my blog. Hi, this is frank and I make these bikes. Please push the "OK" button. Thanks.

I am building a new tandem (when I finish the steel hardtail light freeride and snow bike) and while I am doing the slalom bikes.

July 4th

2011-07-05T02:10:00.000-07:00

Did you have a great weekend? I headed to Plattekill for some riding and visit with some old friends. I got a few runs in on Saturday. The weather turned rainy that evening and the clouds and rain stayed all day Sunday. I took a long nap in the front seat of the van.

Yesterday was a good ride day. I think we did about 65 miles. Nice and sunny! There were lot's of cyclists as well as cool cars and motorcycles out enjoying the good weather.

Heading in this morning to make a snow bike and a steel hardtail freeride later this week. I like this.

Steve

2011-06-28T13:41:00.000-07:00

As many of you know, I have been hanging out at Plattekill bike park for a number of years. If you spent time at Plattekill riding some of the best DH trials in the area you likely rode a trail cut by Steve Porraro. There have been a few course builders over the years and Steve was one of the best.

I have some bad news for you. Steve passed away suddenly a couple of weeks ago. 38 and a national DH champ. Steve is the guy with the Hayes brake rotor zip tied to the grill of his brown van.. Ya, that Steve.

I knew Steve well enough that I also know he would be stoked to see us all at Platte this weekend for a race/party in his honor. I am going to toss some parts together and race this weekend. Please join me and Steve's other friends and celebrate his life at Plattekill this 4th weekend.

mystery

2011-06-27T09:11:00.000-07:00

I couldn't figure out why my fingernails seemed really thin. I thought I needed vitamins or something

Aluminum 29" MTB

2011-06-23T16:16:00.000-07:00

I have some exciting news for 29" wheel fans in the crowd. I have a limited quantity of a butted NOS 6061 tube sets that will build an amazingly durable and light trail-duty 29. The chain stays are tapered rectangle s bend and should provide for short stays and ultra rigidity. The front tubes are bi-ax ovalized and the set will be rounded out with an all new dropout, head tube and BB shell.

I am thinking of utilizing a tapered head tube. Wouldn't that be fun?

speaking of Pauls

2011-06-20T16:15:00.000-07:00

I have been having an ongoing conversation with Paul components and I am wicked pumped to be able to offer my customers Paul components with your frames. We are starting to build a pretty good list of component suppliers.

So we have an idea what Lee has in mind by reading the comments below. It sounds like a good reason to taste blood in your lungs on the short trip home from work or across town.

Speaking of blood, I nipped my finger pretty well while working on this fella last week. 'better than a nail through the knee-cap for sure (let me tell ya) anyway, this 'lil gem is heading south for an ultra-marathon in a few days. It's a 650B machine with huge tire clearance. The seat angle is a bit relaxed but hey I don't pass judgement here.. just call it as I see it..

These are a pretty amazing set of tubes here. I like working with this stuff.

.

What the hell is it?

2011-06-16T03:14:00.000-07:00

My good friend Lee Walker paid me a huge compliment by letting me build him a bike. It is an interesting mix of technologies or philosophies or whatever. Here are some build pics. Perhaps Lee will chime in and tell us about the rest of the built. In the mean time, enjoy these pics.

club ride

2011-06-11T17:02:00.001-07:00

27 203, originally uploaded by frankthewelder.

I rode with the Monadnock cycle club last week. I rode faster that ever before. It was hot and I didn't bring enough water. The road was very rough. I had been riding a loaner carbon fork up to this point but switched to this steel fork. I was pleased with both of the forks performance.

I will do better next week.

FTW burger

2011-06-04T15:41:00.000-07:00

1/2 lbs. ground round
1/4 lbs. Chorizo
1/4 lbs. Cheddar cheese, sliced super thick (1/4")
1 teaspoon Zatrains creole mustard
grinder roll
mayo
1/2 yellow onion
3 large 'shrooms
hand-full spring mix
Pinch kosher salt
fresh ground pepper
1/4 stick real cow butter

Pre heat iron skillet
Mix beef with chorizo, add pinch of salt and decent amount of fresh ground pepper. Make a patty 1" thick to fill the fry pan most of the way.
get skillet smokin' hot and throw in butter, onion (chopped) and after 5 mins, mushrooms. Open windows and remove batteries from fire alarm.

When sticky goo forms at bottom of skillet, move onions/shooms to edge of pan, throw in patty of meat. Skillet should be really hot. Sear bottom of patty and flip (3 mins?), sear other side and bury in mushroom onion mix. Reduce heat to simmer (if you are not using iron, you may need to watch heat), cover and let it go for a while. add cheese pieces bigger than patty so that some melts to fry pan.

Take grinder rolls, split and smear one side with with mustard and the other with mayo. cut 1/4 of patty off and put aside for kids or dog.

Cut remaining meat in 1/2 and place on grinder roll with meat touching the mayo side and cheese touching the mustard.
Add hand full of greens and serve.

Pour a stout and nail it.

Magneto

2011-06-04T14:36:00.001-07:00

It has been a long time since I built myself a road bike. The last time was one of several I built from the prototype tube sets I got from Easton back in 1994. I was contracted to build a frame or two for a female athlete for the Ironman race. I remember working on my frame with a cast on my wrist. Not sure how that happened.

Anyway, I sanded all the tubes and polished them and filed the welds around the dropouts. I rode it a few times but lost interest.

I started getting "interested" again about a year ago when I ended up with a Raleigh road bike from the 70's. I fixed it up a bit and started logging some miles. I got a better bike and rode even more. Even though I haven't ridden a ton of road, this thing is wicked fast. We will talk more after dinner.

26" hardtail trail bike

2011-06-03T17:15:00.000-07:00

When something works, it just works. I need to build myself one of these. I think I am going to use an ENO hub and hammerschmidt in the front. I think the frame will be just under 5 lbs and do a good day's work.

Please enjoy these pics.

N3W

2011-06-01T02:10:00.001-07:00

tacked, originally uploaded by frankthewelder.

this lucky ARC received a new front end yesterday. Soon it will be home with it's family and beginning it's return to a normal life. Several specialist' were present during the process. One made tortillas the other, guacamole.

2011-05-30T15:07:00.000-07:00

oh what should I do.

2011-05-30T14:53:00.000-07:00

so, I have decided to try to get more out of this blog by doing something, not sure what. I have been riding a lot and making bikes so I figure as long as I am doing the right things, the rest will work it's way out. Russ, Lanie and I all went for a good ride yesterday. Although the group was a bit smaller than last week (Peppermint Patty went to see Willy Nelson), this time we didn't have any punctures. My cranks started squeeking a bit but I ignored it.

I built a new FF for myself from Columbus Zona tubes. The frame and fork are TIG welded and painted Hawaiian blue. Sram RED shifting and cranks, Campagnolo Fulcrum wheels and Thomson post and stem.

I went with compact front gears and the 11/26 cogs for a decent range for the local terrain. My lowest gear now is a 42/26. I am pretty excited about this build. The top tube is 575mm so I call the bike "575".

I might try the Keene group ride wed. Ill keep you posted.

The weatherman

2011-05-14T05:27:00.000-07:00

'nothing to do with weatherman at all. The conditions change indoors as much as they do outdoors here at my shop. Some of it is the weather and as you will see, some not.

Starting in January it's already cold. I have to take out the trash a lot because I am eating a lot. The windows are covered with ice and most of the light is artificial. I set a lot of things on fire regardless of the air polution factor. Fire is warm.

Different people visit in the winter. I get more locals when the sugar season starts and cyclists start in after that. Now that the weather is good enough for epics, I get dirt bikes and ATV's that need a broken part fixed. It's also garage sale season, which I enjoy early Saturday. I sort of doubt it is going to happen today though. The van needs and inspection (I never get pulled over in town) but I don't like to break those rules if I don't need to.

I have the back door open and people are picking up their storage items and a couple of people work on project back there, working on boats and what-not. I need to collect some rent too.

If things go good today, Dave will get his solar frame (this giant solar panel frame I made) loaded on the truck and by noon or so, Lanie and I will be out on vintage bikes doing a ride with Russ and Monica.

I just noticed that people have left remarks to some blog posts. Feel free to comment if you like, I will try to reciprocate if I can figure out what you are talking about.

. I don't really know what people come here for exactly but I am going to try to modify my "crap-flow" or whatever it's called, the thing we do with presenting yourself on the internet. I think two flickr accounts, a blog, FB, tweeter, two emails, cell phone, FAX and several forums is too much.

May be there is some way to integrate it without flooding the world with repetitive non-sense. Lets think about that.

by the end of the day

2011-05-03T03:16:00.001-07:00

27 035, originally uploaded by frankthewelder.

I had the fronts welded. I will now inspect and align these before welding the back on.

Large Mategua frames

2011-05-03T03:15:00.001-07:00

27 032, originally uploaded by frankthewelder.

I know it's not fair to show you bikes that are already sold but it can't be helped. Many of these are for our European distributor (FRO imports).

new post

2011-05-02T02:45:00.000-07:00

Great weekend. The weather was awesome and I went for a huge ride. I have a lot of production this week on the Mategua frames as well as some unique 4130 and Zona frames.

I have a Bi-laminate constructed frame (lugs made from tubing and fillet brazed) soon also that is going to be a lot of fun. I have been practicing brazing quite a bit. Fillet brazing was the first welding skill I practiced. I started out working on bikes by repairing sting-ray frames in the 70's.

I have some pics saved up to post. I am thinking about going to a wordpress based info site also. I should wait on that till winter.

Torch

2011-04-23T17:40:00.001-07:00

23 016, originally uploaded by frankthewelder.

This is what it looks like without the ceramic cup. The argon comes through the screen which helps prevent oxygen contamination. This rocks! Notice the high-didge silicon flexible torch head and crusty welder fingers.

WP-20

2011-04-23T17:38:00.001-07:00

23 015, originally uploaded by frankthewelder.

This is my TIG torch. The amazing Weldcraft WP-20. There are some good welders that don't use this torch. I find that amazing.

I use a gas lens and #7 Alumina cup. The electrode is 3/32, 2% thoriated Sylvania precision ground 7" model.

headtube

2011-04-23T17:35:00.001-07:00

23 013, originally uploaded by frankthewelder.

I remove some material from the front of the headtube on these bikes. In fact, I mess with everything.

dropout tacked

2011-04-23T17:34:00.001-07:00

23 012, originally uploaded by frankthewelder.

Close up of the Mategua dropout

Mategua

2011-04-23T17:33:00.001-07:00

23 011, originally uploaded by frankthewelder.

this is Guido's frame in process.

Mategua

2011-04-23T17:24:00.002-07:00

The latest work is the 7005 Mategua frames (29) and a special batch of a burlier 29" frames. What you see in the image now is Guido's Mategua frame. Guido requested Cantilever brakes and the factory bent seat stays would not be suitable.

Trials frames

2011-04-23T17:24:00.001-07:00

23 005, originally uploaded by frankthewelder.

So I got these done and gone. The next thing on the list is the 7005 frames.

assorted tubes

2011-04-14T16:57:00.001-07:00

assorted tubes, originally uploaded by frankthewelder.

tubes for the next several days. some crazy stuff in there.

WTF stock trials frames

2011-04-14T16:42:00.001-07:00

21 014, originally uploaded by frankthewelder.

The most durable trials frame on the market.

Bullseye cranks

2011-03-22T16:07:00.001-07:00

13 003, originally uploaded by frankthewelder.

Just like the old ones. Genuine G1 Bullseye cranks.

Back to work

2011-03-16T03:29:00.000-07:00

I just got back from visiting my mom in California. She turned 90 last week. I also saw a few old friends and more relatives. Flying sucks but the trip was awesome.

It's always nice to have a bit of time to let the mind coast a bit. I read a Jon Krakaur book and took several naps.

I am hammering the 6061 stuff right now. Bullseye gets started today and I have to unpack a bunch of inbound packages.

Tuesday

2011-03-01T02:35:00.000-08:00

Getting rolling on the CNC with some aluminum dropouts. Buddy (my dog) is now bugging me, I guess it's time for his walk.

Ill try again tomorrow.

B-fun

2011-02-24T02:29:00.001-08:00

7 008, originally uploaded by frankthewelder.

take a look at this frame. I really like it!

http://www.flickr.com/photos/frankthewelder/sets/72157626126694370/

brazing

2011-02-21T15:13:00.001-08:00

7 005, originally uploaded by frankthewelder.

Today was an awesome day. I really turned a corner today with my gas brazing. It's a great day when you get lost in your work and when your day is complete, your stuff rocked and you are beat.

shapley tubes.

2011-02-18T03:41:00.001-08:00

6 004, originally uploaded by frankthewelder.

I made this frame from 7005 oversize for Spooky bikes. I think it has some nice lines. I added curved bridges at the end of the day.

Frozen treat

2011-02-10T14:59:00.001-08:00

5 004, originally uploaded by frankthewelder.

This morning when I left the house it was unusually cold. I didn't check the temp but I could feel it soak through my clothing after about 5 mins. of walking. I was worried about buddy freezing his toes but he didn't seem to mind.

I completed a cool project today. I build a bike for one of Mickeys customers. The frame is a custom cyclocross frame for a fella in Texas. He needed some extra clearance so I got about a pencils thickness around a 37. The frame came 1375G with canti mounts. Buff-ola.
http://www.flickr.com/photos/frankthewelder/sets/72157625895599045/

Mategua. In the flesh

2011-02-10T01:55:00.001-08:00

4 016, originally uploaded by frankthewelder.

Here is a pic of one of the finished frames.

Mategua

2011-02-06T05:27:00.001-08:00

3 002, originally uploaded by frankthewelder.

We machined only the front of the 7005 headtube. It saves a few grams and sacrifices no strength. The top of the DT is thick enough and not require a gusset.

nice metal

2011-02-06T05:23:00.001-08:00

3 008, originally uploaded by frankthewelder.

It was fun welding Mategua frames yesterday. I improved my 7005 chops by adjusting the wave balance to a greater degree of reverse polarity. I guess I use more of less.

Hidden agenda

2011-02-04T04:14:00.001-08:00

2 021, originally uploaded by frankthewelder.

This the weld that is under the downtube on these bikes. From this view you can see that I widened the base of the seat tube. This transmits just a bit more of the load further up the seat tube, away from the weld at the down tube.

Some cat has been pissing in my shop. That isn't cool.

Head tubes?

2011-02-04T04:11:00.001-08:00

2 020, originally uploaded by frankthewelder.

Did we talk about these? Sure we did. This is how it will look on the bike. As you can see, my thumb nail grew back.

ready to go

2011-02-04T04:09:00.001-08:00

2 018, originally uploaded by frankthewelder.

Actually, they still need to be scrubbed again with "virgin" abrasives. It's all part of the secret sauce we spread every day.

lathe army

2011-02-04T04:07:00.001-08:00

2 019, originally uploaded by frankthewelder.

I love machines. I mean I like them a lot. There is also a couple of horizontal mills in view.

and this

2011-02-03T04:01:00.001-08:00

`sample pics 010, originally uploaded by frankthewelder.

THIS is the rest of what I did yesterday.

2011-02-03T04:00:00.001-08:00

`sample pics 009, originally uploaded by frankthewelder.

this

everything I want

2011-02-03T03:59:00.001-08:00

`sample pics 007, originally uploaded by frankthewelder.

I wanted to get a bit more room for the tire and chainring than would be possible. I added a bit of a "dip" where the tire is closest to the chainstay and added further clearance by shaping the tubes like the letter "D". Now, I have everything I want.

headtubes

2011-02-03T03:55:00.001-08:00

`sample pics 005, originally uploaded by frankthewelder.

so here ya go.

and a bit more.

2011-02-03T03:43:00.000-08:00

Here are a few pics of yesterdays festivities on the Mategua. These bikes are build to team geometry but are also available custom sized and spec'd for you. Max worked on these headtubes while I did the chainstays. We off-set the three jaw chuck a bit and did the same type of cut that I often do, except offset a bit. I like the look of the cut and removing the material but these are a bit thinner to begin with.

`more of the white metal

2011-02-03T03:39:00.001-08:00

`sample pics 006, originally uploaded by frankthewelder.

Greetings friends! We are off and running with the first aluminum build of the season. I have a bunch of 29's going on as well as some other interesting things. These are new bikes for this season, crafted from 7005 butted tubes are called "Mategua".

Close by my shop someone carved an image of a rabbit into a large stone. I read that those ealry locals called rabbits Mateguas. Other people claim that these people lived at the very location of my shop.

today

2011-01-11T03:27:00.000-08:00

Steve is coming by today so that I can drill and tap a couple of holes. I am not sure if it's a bike or what but it will be nice to visit a bit.

I am making a few pieces for Trout river today. I hope to be paid in beer. I modified a bottling manifold and am building a pump stand. Don't you wish you were me?

head badge

2011-01-05T15:00:00.001-08:00

IMG_4038, originally uploaded by frankthewelder.

My friends at Kiosko in Springfield VT cut a few logos out of some .040" stainless steel. I first formed the pieces in the press to fit the head tube.
I then silver-soldered them on to a head tube drop (metal worker lingo for the piece that is left over after the piece you need is removed). I also had .040" holes cut in a couple of places for the alignment pins (nails as they call them). You can see the rest of the pics by following this link.

Indy Fab

2011-01-04T02:43:00.000-08:00

Hi everyone! I went to Indy fab yesterday and did a few things. I practiced a bit and did the first pass on a frame (welding logo man, some Ti frames get two "passes", one tiny weld first and then one more robust). It's a nice shop, bigger than mine with more people. I met nice folks and viewed some sick bikes.

I got to meet the departing welder who has been laying down gold for Indy for years, Tyler Evans and see some more of his handy-work. I also saw some upcoming projects that will blow your minds.

Gary, the guy who owns IF contacted me a few days ago and asked if I was interested in welding some bikes for him. Over the years I have always jumped at the opportunity to work with others and it was a blast. As you might imagine the setup is a bit different. I use a different torch that is a bit more flexible and lighter. The one I use wiggles a but from the water flowing through it (yes, mine are water-cooled) which may be less desirable. I know it was so quiet I couldn't tell the machine was on. You must use a water cooled torch with aluminum but as you can imagine you get a steam shower once in a while when you puncture.

Just so you know, I am NOT going to be building ti bikes at my shop. It's fun to weld but that is it for me.

I am doing a bunch of 6061 bikes coming up soon and now when I go to heat treating in Boston I will make some bank and get some schwag.

2010-12-30T02:52:00.000-08:00

We finally got some snow. It's a bit of a relief actually. It seems to be a bit warmer in the shop when there is a layer of snow blocking the wind.

I have been putting the final touches on a solar panel tower (for lack of a better description) for Dave this week. Lots of big pieces of metal.

I went up to Trout river brewery yesterday and met all those folks. Nice people, brought a new beer home to sample.

Time to walk Buddy.

2010-12-23T02:51:00.000-08:00

I should have cut tubes today but I finished a chainstay mitre fixture I have been working on. This will help perfectness.

I am a bit tired today. I worked really hard for many hours yesterday. It was fun.

2010-12-18T04:13:00.000-08:00

Here is a Pic of one of the road frames finished. I really like the way it came out, it's very light and feels amazing in the hand. I haven't started on mine yet (I have two planned for myself, I know..selfish) I have some fun ideas I am looking forward to trying out. The difficult part of experiments with this material is wasting expensive tube while you are trying to work out shapes. I am going to do a bit of it anyway.

I started working with another rider/customer a couple of days ago. A retired road pro who specifies and assembles cycles from an eclectic mix of components from both large and small builders. I am flattered to be selected as a favored builder. I will be building full custom TIG welded COLUMBUS Zona tubing/Paragon fittings frames built to the individual riders needs. This is awesome as I prefer to focus on construction and not fitting.

I spent some time this week repairing some old frames. The forensic science of frame repair is the best part. Seeing what other builders did (or didn't) do during the original build. You also have to smell a lot of burning paint and deal with contaminated surfaces and that would be the least desirable part. I have a lugged frame that needs a rusty tube replaced some time in the future.

I repaired a badly dented top tube on a vintage Raleigh Professional also. I tried something unique and filled the tube with air pressure and used a bit of heat on the dent. I think is was less traumatic to the frame and certainly took less time than a tube replacement. It came out quite nice.

brake time

2010-12-10T13:27:00.001-08:00

IMG_4000, originally uploaded by frankthewelder.

In my best interest to get a new camera. If they can make one that eliminates red-eye, then why not metal reflections?

So, I TIG'd the brace and brake on with silicon bronze. It's super strong. It's very challenging to use however.

IMG_3999

2010-12-10T05:15:00.001-08:00

IMG_3999, originally uploaded by frankthewelder.

looks awesome this way too!

my apologies.

2010-12-10T05:14:00.001-08:00

IMG_3998, originally uploaded by frankthewelder.

I can't leave things alone. I reversed the oval back toward round where it joins the BB.

2010-12-08T13:48:00.000-08:00

I got all the metalwork done on Matt's bike this afternoon. Brazing the collar sleeve was more difficult that any of the braze-ons. I know what I will do different next time. You need to have a good bit of seat tube sticking out the top of the sleeve to make it easier to slide the silver in.

After the brazing I clean up by sandblasting a bit. Now my ears are full of sand.

1618 gram road frame.

2010-12-08T06:22:00.000-08:00

I tried to post another batch of pics yesterday and it didn't work. Ill clean this mess up after the weekend.

I spilled a bottle of argon last-night by leaving the purge on. I had a big mess to clean up this morning. I am surprised it didn't put out the pilot on the heater (also left on).

Someone remind me to not just drop my tools and walk out the door at the end of the night.

2010-12-07T10:27:00.001-08:00

http://www.flickr.com/photos/frankthewelder/5241809488/in/photostream/

2010-12-07T10:26:00.001-08:00

2010-12-07T10:20:00.000-08:00

I am really happy with my brazing. The lines came out really sharp.

silver brazing

2010-12-07T10:18:00.001-08:00

IMG_3960, originally uploaded by frankthewelder.

I was a little apprehensive going into the silver portion of the construction. I first silver brazed under the guidance of David Tesch during the time I was in Arizona. Dave passed away a few years ago.

It only took a couple of warm-ups on scrap tube before I felt really good with the torch.

welding a road frame

2010-12-04T04:52:00.001-08:00

welding a road frame, originally uploaded by frankthewelder.

I have the chainstays on and ready to tack. The tape is to prevent the gas from leaking out of the frame.

second mitre on chainstay

2010-12-04T04:50:00.001-08:00

second mitre on chainstay, originally uploaded by frankthewelder.

Here is what that looks like up close

IMG_3927

2010-12-04T04:49:00.001-08:00

IMG_3927, originally uploaded by frankthewelder.

Now the chainstay is held by the dropout to both can be mitred at the BB to the exact length. I zero the DRO, tool comp then set a P-drill at the BB. Clear as mud.

burly dropout weld

2010-12-04T04:46:00.001-08:00

burly dropout weld, originally uploaded by frankthewelder.

Here I have welded the drop to the tube. The material that the drop is made of is not the same as what the tubes are made of. It's plenty strong but welds a little weird. Much better than the 1215 that they spin the bridges and cable stops from.

purge and weld the dropout

2010-12-04T04:43:00.003-08:00

purge and weld the dropout, originally uploaded by frankthewelder.

After tacking the drop, I hook up the purge line and weld it. -

IMG_3921

2010-12-04T04:43:00.001-08:00

IMG_3921, originally uploaded by frankthewelder.

After the mitre the tube is deburred and polished inside and out. In this image I have the dropout and tube clamped in the same tool seen in the earlier image.

crimping and mitring chainstays

2010-12-04T04:40:00.001-08:00

crimping and mitring chainstays, originally uploaded by frankthewelder.

The next thing is to cut the small end of the stay to fit the drop. This fixture is modular so many types of operations can be performed on several types of tapered/bend/shaped chainstays.

The small aluminum blocks that grip the tube and made on the CNC mill to allow me to grab the tube firmly and without damage.

The drop is a hooded type.

crimping and mitring chainstays

2010-12-04T04:36:00.001-08:00

crimping and mitring chainstays, originally uploaded by frankthewelder.

I took a few pick of the work I did yesterday. I first cut the overall length of the chainstay on the chop saw. I couldn't take a pic and cut at the same time so you will have to take my word for it.

Were I am putting in a shallow crimp for tire and C-ring

road and CX build pics.

2010-12-04T04:27:00.000-08:00

Here are the pics I promised. I know it's tough to view images with all the background clutter but here they are.

2010-12-02T02:46:00.000-08:00

Hi, I spent the last couple of weeks making new tooling for building steel bikes. I have been using the Anvil fixture for building lately. "What?" you say? All those custom fixtures and you use a commercial fixture?

I like this machine. It's really easy to set-up and the rad thing is the frame can be completely welded in the fixture AND fully purged to boot.

Micky at Spooky produced the frame geometry for this bike and I did all the rest of the stuff. I wanted to build a "throw away" (or sell cheap) practice frame so I can see how this material handles in process. After reading the material specifications and properties if this Columbus Zona tube I thought it would be harder to mitre. It's pretty nice actually.. pics to follow.

winter

2010-11-08T06:33:00.000-08:00

Is here. I tried buying a big propane tank to heat the shop with and the local dist. told me to go to Home Depot and buy one of their cylinders. I don't know where the closest one is..

IMG_3738

2010-10-19T09:30:00.001-07:00

IMG_3738, originally uploaded by frankthewelder.

Imagine my surprise to find a box of fine bicycle tubing ready for fabrication. I think I will take a nice walk before I begin.

contact

2010-10-12T04:35:00.000-07:00

my email is franthewelder at comcast dot net and my phone number is eight oh two 376 6639.
I use my real name on facebook and the team uses this page

I also have a domain, frankthewelder.com that needs some updating

thanks for looking!

Your welds

2010-10-12T03:56:00.000-07:00

Since I started TIG welding in the late 70's I have used certain products that I know and trust. Like driving your personal car, you know when something isn't right. I have tried several different type of electrodes with different blends, finishes and diameters. The worlds best electrode is manufactured by Sylvania Osram corp. right here locally in Hillsborough, NH.

I never knew when I started this type of work that expanding would also involve "getting local". My local welding supplier who carried or would get the stuff I feel is important. They were purchased by a larger company and everything is supplied through a logistics and distribution company. I am used to paying $75.00 for 10 pieces of jewel like Sylvania thoriated tungsten supplied in a nice wooden divider to prevent damage. The electrodes are polished and all perfect diameter. This provides a beautiful conical arc (most importantly) but being perfectly ground to size, does not slip from the torch and fall into the molten puddle leaving 2" of heavy radioactive metal in your frame.

The import stuff is marginal at best and I really don't want my radioactive material being handled by a manufacturer that isn't regulated. It's no secret that we have to protect ourselves these days with the agencies that protect us are being gutted in the name of profit. There were many good years when the import crap sold for $6.00 per box and stunk like rotten fish but you could still get the good stuff.

The supply chain was temporary broken yesterday when my usual supplier only had import stuff. In a pinch I might buy a box of the crapola and later use the remaining 'trodes for poison darts or something but now the china stuff is $35.00 a box.

Yesterday, I tried again to buy from another trusted supplier from the old days. He has some CK, made in USA for $45.00 a box. I ordered a couple of boxes and much to my dismay I found that CK is in-fact imported while searching for Sylvania. OK, so it's not the cheap chinese stuff. It's the expensive chinese stuff. But wait, It was $8.50 a box from an online source.

The good news is I have always supplied you with the best materials I could get and you (we) are used to paying $75.00 a box for the stuff. So, nothing has really changed. Or has it?

So, now we have retailers buying low price stuff and ratcheting up the price. Where does that leave us? I found my stuff and solved the problem temporarily but you and I are being pinched in the middle. I have drawn a line in the sand and will likely always have purchasing choices (US industry is holding it's ground somewhat at this point)

I am glad you are willing to let me make your bikes. I think constantly striving to improve my product and service is the only way I can truly support our economy and sport.

more bikes, more metal.

2010-10-11T15:23:00.001-07:00

I shipped a bunch of bikes the past few days and am happy. A bunch of the old repair/refurb jobs are back from paint and those will get boxed and kicked out the door this week. I had a great talk with Lon over at Nova cycle supply. When I buy butted tubes, I get them from Nova. I have some 'cross bikes going right now and I also picked up a few Columbus Zona kits for road bikes. I got one for myself that I am going to do with lugs. Nova has been working on a stainless lug set that should be pretty sweet. I am going to make the drops from 1020 steel then skin them with stainless. This will allow me to polish the lugs and dropout surfaces and paint the main tubes whatever color I choose. The Nova lugs are thinned toward the ends and have some pretty big radii where the end of the sockets are. I won't go nuts on the cutting so I can get right to the fun stuff.

I haven't welded a steel frame in some time but I have been keeping tight with other steel projects. I am looking forward to the steel work.. it's about time huh?

IMG_3586

2010-09-07T16:13:00.001-07:00

IMG_3586, originally uploaded by frankthewelder.

see what I mean?

MY SHOP

2010-09-07T15:56:00.000-07:00

My shop is officially a disaster area. I planned on cleaning it this past weekend but I got a little side tracked when the nanny wheel on the CNC was causing a fault. I ended up having issues with both X and Y axis units randomly on the same day. I got the issues resolved early this morning and was off and running again.

I finished all the shuttles, received 25 axles and 15 pivot axle assemblies today and got the hangers about 1/2 way done. I didn't hear from the machinist who does my lathe stuff after a few calls and was starting to freak when the stuff arrived. I am having GSP put .001 hardcoat on the pins and caps. I get a bit less on the axles. This seems to get a primo fit to the bearings.

I am getting closer to beginning the 4130 stuff as the FB-10's wind down and they each go to their new homes. I should be picking up the painted FB-10 pieces tomorrow or Thursday.

Stem sell research

2010-08-30T11:34:00.001-07:00

IMG_3580, originally uploaded by frankthewelder.

I made a couple of stems. The clamps are fully CNC machined from billet 6061 T-6 and tig welded to a nice piece of aircraft grade drawn tube. I made a spare for you. It's 100mm with no rise. Actually is has a little offset for +/- 10mm. Here is a link to view more pics of this being fabricated. Lemme know. You have my number.
http://www.flickr.com/photos/frankthewelder/sets/72157624717745733/

fixed

2010-08-27T05:04:00.001-07:00

IMG_3568, originally uploaded by frankthewelder.

Yesterday I had a blast repairing some old Spooky and Sinister frames. The one to the left is for my buddy Chris. This is a later model frame and in pretty good shape. It's getting a better brake mount (bolt on) and some new welds on the side gussets. Steve's, a very early model is in the middle. He got a new seat stay tube and brake boss. After heat, a new coat of paint.

The Ridge also an older unit needed a new dropout but last month was double-secret free .875X.875X.065X.125R 6061 T-6 custom drawn short piece of tube month so this lucky fella got a whole new backside. The truth is I don't really like that sharp corner tube on the old sini frames and it's easier to just blow the whole ass-end off and replace it in this case.

I am making a couple of custom aluminum stems. They will be for 31.8 bars and 1-1/8 threadless with a four-bolt removable CNC'd bar clamp and two bolt knee-buster steerer clamp (which I call all rear facing types) with small M5 stainless bolts. They will be welded with 1.5" extension tubes to full radness.

One is still available for custom sizing until I get to cutting the extension tubes. Then I will just guess at a size and will measure it only when it's done just to show you how crazy I am today and may be tomorrow till about noon or I get tired.

They will be available raw tumbled and or powdered to suit. I have only built one other stem since 1992 so it's on a short list for sure.

$300.00

crap

2010-08-23T03:57:00.000-07:00

ran out of welding rod and went to open a new box..1/8" OH NOOOOO!

S.L.A.C.K.E.R.

2010-08-19T03:38:00.000-07:00

sorry for not posting. I have been so busy getting the FB-10's done, I forgot to mention 29's. I have some more coming up. I am thing some steel would be fun too! Lets think for a bit.

Going big

2010-07-21T12:38:00.000-07:00

That's right folks, it's 29 time again. I am building some right now (which you may have missed out already) AND and I am building more! Also dabbling with a "hevae dutae" version for larger than average fun. pics to follow.

2010-07-06T01:35:00.000-07:00

sorry about having dump that film. It seemed to block the whole page.. you can see it my flickr site.

fingers update

2010-06-29T03:20:00.000-07:00

I did some early testing yesterday. I am still running O.S. at this point. The pivot seems to be a bit tight. I am getting about 25 degrees of articulation. I tried increasing the pre-load and massive amplitude change in feedback from my real-time data acquisition (pain). Vibratory testing revealed micro-fractures in the substrate that have not been bio-re-mediated at this time (don't touch broken bones to vibrating machines) . I don't think any increase in leverage ratio would be wise until those issues are addressed (don't push too hard, it'll break again) .

Continued chemical and thermal conditioning is yielding excellent results. I now eat so many Tylenol I can drive nails with my skull. LOL..

actually I can weld a bit, just not very well..

IMG_3375

2010-06-25T11:10:00.001-07:00

IMG_3375, originally uploaded by frankthewelder.

Jimmy Mac. 'Nuff said.

'getchur bearings

2010-06-21T04:09:00.000-07:00

The tracking info says they were in Nashua NH at midnight last night. I think they will be here today. I am sure the hard anodize is done also. Lets ship some bikes..!

FB10

2010-06-17T06:54:00.000-07:00

whew, it's been a crazy month. I had to run the swingarms back through heat treating and had some delays with getting bearings and pins here. Fortunately, I was able to fit the swingarms in the vibratory finisher for a sweet finish. Enduro is 2nd day shipping bearings that should be here on Friday. I am picking up some pins in Mass later today and GSP runs a second shift on Thursdays so they agreed to get the hardcoating done by Friday, first light.

Max's bike is assembled with a 09 Boxxer and Rocco shock. I took some measurements (it's a medium) and here is what we have.
With the fork slammed on flat crowns and the steepest of the three positions being used on the shuttle the head angle is 65.5 degrees and the BB rise is 1" (13.5 tire radius +1"= 14.5" at full top. The chainstays are 17.4" and the wheelbase is 47.25

If you were use the slackest shuttle position with a slammed fork you would get 1.5 degrees slacker head angle at 64 degrees. sliding the fork out of the crowns a bit can get you out to about 60 degrees if so desired. I will likely make another batch of shuttles with one degree of adjustment per position. We will also make one for shorter shocks though you may be able to use this one reversed with a 8.5" shock for 7.5 of travel. Once the main shape is done variations of that is easy.

I didn't ride it myself (smashed the crap out of my hand last Saturday) but Max and Becky reported back that the bike was quick and initial set-up of the shock was straight-forward. I watched Max do several sprints and the bike accelerated very quickly and without bobbing.

Becky raced last weekend and claimed to have amazing speed on the bike through the BMX type obstacles. I am stoked because i pushed the pivot as high as I could to produce the best shock rate available to a linkage-less design. Again with sub 8 lbs frame weight and nearly zero suspension drag This means combined with the very low unsprung weight and neutral pivot the bike will require only minimal damping and have wicked fast suspension acceleration to keep the wheels on the ground. This will improve traction (specially in corners) and reduce the likelihood of punctures and wheel damage.

Enjoy your day, more pics and info soon..

side view

2010-06-04T15:08:00.001-07:00

IMG_3277, originally uploaded by frankthewelder.

very low CG and stand-over height.