1st Frame Build. A progress log/"build thread"

[zank]

SWEET!

A regular plastic under BB guide should work. It should flex to match the shell OD.

[mmoore]

I have a plastic one for the English BB, but there is no way in heck it would flex to a PF30 shell. maybe if I put it in some boiling water and pressed it on...


Im going to talk to the LBS when im down there... he might have something in stock that will work. The guide from my carbon Giant looks like it would work great because it has an oversized BB area.

[Jussi Kettunen]

Color looks great!

[mmoore]

Color looks great!

Thanks! It should look great with the black accessories.


Im trying to convince myself I don't have the right RD for the range of gearing I have.
52/39/30T chainring with 11-28 cassette. I have a short cage RD6600... I don't think its going to work.

[mmoore]

Tonight I am building my stoker's stem. Took my CAD sketchup and it will be ~190mm C-C. Im hoping this works with enough clamping force to not move... if it doesn't work out I have no problem buying one. BUT I have the skill AND the material in stock to pound one out in an evening. I will post updates if it ends up working out. LOL.

[progetto]

I would be looking for a builder rather than a machine shop to finish off bearing surfaces, dedicated tools are much safer.

[mmoore]

I did try to find a builder.


There is noone that I could find that had the pf30 reamer, 44mm ht reamer nor a 27.2 post reamer.


I feel like I have exhausted options and I would never ask to borrow tools since I know that never works well.


I may call someone in the Toronto area to ask but that's a long reach for a small service.

[mmoore]

Stoke level infinity.

Powder guy sent me these... but then said he wanted to re-do it because he wasn't happy with a little part that would have left me plenty happy with either way. Hes just starting out with his business so he wants everything leaving his shop to be absolutely perfect.

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[werksmini]

Looks awesome, can't wait to see if built up.

[mmoore]

Looks awesome, can't wait to see if built up.

Thanks,

I cant wait either.

Im going on my lunch either ...now or tomorrow to grab the build kit that the LBS has setup for me.

Using a wheels MFG PF30 eccentric bb for the front crankset instead of some other type of aluminum insert with a set screw
Cane creek 40 series tapered headset
FSA SLK cranks (megaexo rear BB), standard SLK crank reversed with a 42t chainring for captain.
BB7 road brakes
105 5703 "group"
the pictured Alexrim DA22 for the time being
stoker suspension seatpost and aluminum bullhorn bar
captain will have a solid seatpost and a compact ergo drop bar


A pretty basic build... not a high budget build by any means, but most importantly it fits us. Any tandems we took out the stoker compartment was way too small.

[mmoore]

"What iz dis?"

20150611_214238.jpg
Powder looks great. I'm not going to be too critical but there were a few spots that made it obvious that it wasn't a pro powder job. Namely around the bottom bracket and chainstay bridge. He has some gear to prevent the" Faraday cage" from doing this with the powder so I assume it's just technician error or oversight. Not the end of the world, but too bad.

Heading to my lbs today to have the English bb chased. Then I will swing by my favorite machine shop to see if they have a reamer that will work for the head tube and pf30 bottom bracket.

If not, I'm going to nut up and buy some pf30 and 44mm reamers. Then have to build a few frames or another turbo manifold to pay them off.


Matt

[mmoore]

Updates too often with useless stuff? tell me to shut it.

LBs is chasing threads now. We tossed it on the scale because he was surprised how "light" it is. 7lbs 11oz (roughly 3400g). not bad for largely straight gauge tube.

[mmoore]

Back from the bike shop. Starting final assembly of some items while I wait for the PF30 and 44mm Ht reamers to come in so I can finish those joints.

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[mmoore]

Getting closer.
I managed to "hack" together a stoker stem. I was going to build it fully custom, but the hipster bars are partially aero and I didn't notice when I picked them up... so I needed to use a bolted face plate that I didn't have time to start milling. It looks fine now all painted up.






Tried it out on my MTB since it is the only alloy seatpost bike I have and there is lots of leg room for hands back there with these bars and my custom modified stem.

The reamer for seat tube should be in tomorrow, the headtube and PF30 bb reamers are supposed to be leaving Niagara cycle today. the build is nearly complete!

[progetto]

Be careful with that stem if it hasn't been heat treated.

[mmoore]

I did some heat treating of it.... a little complicated because its a mix of 7005 (seat tube portion) and 6061.

Thanks for the concern though. Im confident it will be fine, but I will keep an eye on it and see if I cant twist it with an out-of saddle type torque prior to a ride.

[Rody]

Matt,

One of the strengths of this particular forum is the number of professionals who are willing to share advise, process tips, and business information to help mentor others.

Sometimes, the information is well received and a benefit to others, sometimes it is hard to accept.

I say this because someone needs to; the stem you have fabricated is in no way safe in design or fabrication and SHOULD NOT BE RIDDEN.

Mixing alloys, not adhering to known standards for post fabrication heat treating, and just poor fabrication will result in product failure. Please do not allow someone to be injured during your learning process.

I know that you are excited to get this creation on the road, but short cutting fabrication is not acceptable.

I would strongly encourage you to set this piece aside, re-design, and take the time to fabricate a piece that is sound and worthy of your effort

cheers,

rody

[mmoore]

Thanks for the warning Rody. Im in no means disregarding the warning.

I will grab some new material and rebuild the stem in entirely 6061...

Beyond that, you mention poor fabrication. are you referring to the thought of using different materials, the welding, the position of the joints, etc? This would help with the re-design I believe.

The person using this stem is the most valuable thing to me, im not trying to cut a corner to save a buck or to rush things through in an unsafe manner.

[Rody]

Matt,

The post fabrication requirements for 6xxx series aluminum is drastically different from 7xxx series, requiring a certified process to bring the full strength of the material back. Unless you have access to a sub contractor who is willing to do a furnace/quench run for a single part of your dimension, the cost and logistics become quite prohibitive.

Although you can mix some grades of aluminium, I don't feel that this particular part is a candidate for that. Pick a series that meets your needs; strength, machinability, weldability, post fabrication requirments and make the unit homogeneous.

When re-designing the part, changes I would encorage would include eliminating the tubing butt joint in it's main length, instead building out of a single piece for strength and continuity. You may also consider ovalizing the main body to provide greater lateral rigidity during hard efforts or standing.

Here's a pic of the stem off of our tandem, placed on the frame for strength but also allows the captain to change saddle height without affecting stoker' position. Ovalized for strength, adjustable for rise but not length due to a dedicated stoker.

tandem stem.jpg

[mmoore]

Pulled out the SLR for a quick shoot while I was waiting for the wife to get home.





The seat tubes are now reamed and finished to the proper diameter. Im just hoping that the head tube and PF30 reamers come in before the weekend so I can start the final build.