29 N' Single

[DeeDub76]

I thought I would contribute with a build post. As a newbie I think it would be fun to document a build from start to finish.

So here is the plan. Single speed 29er with rigid fork. I wanted to keep it as simple as possible for my innagural build.
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It is amazing how an person can look at all these great pics on this forum and read all the posts here, but nothing can replace the experience of actually putting your hands on some metal.
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I did manage getting the front triangle all fitted up. The hardest miter by far was the DT to bottom bracket. Ugh! It took me forever, but I learned so much. Good times.
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[Too Tall]

Nice dewd really nice. Everyone loves watching the process.

[afwalker]

Nice looking jig! How are you planning on joining, brass, tig?
More pictures:)
cheers
andy walker

[DeeDub76]

Fillet braze.

Thanks!! The jig is pretty much copied from Kris Henry of 44 Bikes.

More pics to come...

[Will Neide]

The hardest miter by far was the DT to bottom bracket. Ugh! It took me forever, but I learned so much. Good times.
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I don't know if you're doing your miters with a file or mill/drill, but they look good. What I would do if I were using your jig and hand files is I would miter the down tube for the bottom bracket and head tube (not for the seat tube yet). Then I would remove the cone for the seat tube and attach some type of dummy shaft in the appropriate diameter tube (28.6 or 31.8) and lower it until it hits your downtube. Mark that point. Head on over to nova-cycles (Miter Your Tubes with Tube Notcher ! :: Nova Cycles Supply Inc.) and enter in your angles and tube diameters into the notching program for the intersection of your DT and ST. Print your template and tape it to your tube using your mark from the dummy shaft. Cut your notch and it should be a perfect fit providing you did everything correctly.

That may be poorly explained, but that's what I sort of do with my flat plate jig. Works great every time and really eliminated a lot of the frustration for me.

Your jig looks good!

[Jussi Kettunen]

Jig looks great, it's easy to tell where the design is from.
Good progress so far, miters look tight.

I don't know if you're doing your miters with a file or mill/drill, but they look good. What I would do if I were using your jig and hand files is I would miter the down tube for the bottom bracket and head tube (not for the seat tube yet). Then I would remove the cone for the seat tube and attach some type of dummy shaft in the appropriate diameter tube (28.6 or 31.8) and lower it until it hits your downtube. Mark that point. Head on over to nova-cycles (Miter Your Tubes with Tube Notcher ! :: Nova Cycles Supply Inc.) and enter in your angles and tube diameters into the notching program for the intersection of your DT and ST. Print your template and tape it to your tube using your mark from the dummy shaft. Cut your notch and it should be a perfect fit providing you did everything correctly.

That may be poorly explained, but that's what I sort of do with my flat plate jig. Works great every time and really eliminated a lot of the frustration for me.

Your jig looks good!

Or you can use BG101_v801 excel spreadsheet, it can generate DT-ST-BB miter templates. There's also pdf manual available, here

[DeeDub76]

Interesting spreadsheet....I've never seen this. Thanks for sharing!!

[shirk]

That spreadsheet is great. Thanks for sharing.

[Will Neide]

Wow! Someone smart spent a lot of time on that spreadsheet. Very cool!!

[DeeDub76]

Managed to get in a little torch time.
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[DeeDub76]

Layed down some fillets. My fingers are so raw and sore from filing and sanding!
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Have a great week!

[DeeDub76]

The weather was perfect this weekend for getting into the shop, cool and raining. So I got started on the chainstays. What a pain! I have got to come up with a more percise method of slotting for the dropouts. I see too much potential for mistakes to be made when doing this. I used fillet pro for the dropouts. It's expensive stuff, but it worked great.
I spent the majority of last week building a jig for the stays.

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Getting the correct angle for the dropout was a struggle.
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[Todd Mosley]

Nice work! Nice fixtures too - are you making your own?

[DeeDub76]

Thanks for the kind words!

I am making my own fixtures. I enjoying machining and its process.

[Greensabbath]

This frame is sweet. I'm planning on building something like this in the future for myself. What type of dropouts are you using? Thanks!

[DeeDub76]

Thanks Greensabbath!! There is a definate learning curve with this being my first frame. I'm using Paragon sliders www.paragonmachineworks.com - DS1004StainlessSteelFrameComponentsforFlatSlidingD ropoutorderinsertsseparately

[afwalker]

Ok that's a pretty darn good chainstay jig. 8020 but how'd you come up with such a nice one on your first attempt?:) What inspired you? Could and have you used this to do the cuts for the BB? I think that would work fine on a horizontal or vertical mill...
Anvil dummy axle is what that looks like.
Nice
andy walker

[DeeDub76]

Thanks Andy! I've had plenty of time on this forum to try and figure out what kind of fixture I wanted as I have been lurking for well over a year. Also, I had some left over 80/20 pieces from my frame jig. So it made sense to use what I had. It has worked out well so far. I'm hoping to use it to miter seatstays as well. Some slight mods will be needed though.
I did use it to miter the CS.
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[Todd Mosley]

Did you make the chainstay tube blocks or source them somewhere?

[DeeDub76]

I made them out of 1.5 x 1 aluminum bar.

I also made a tubing block for my milling vise. I wouldn't want to do it again. HA!
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