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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 11/14/2015 :  17:58:34  Show Profile  Reply with Quote
Worked on the jig some more today. Made risers for the main tubes. I designed it so that the centerline of the frame is 4" off the base.


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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 11/24/2015 :  05:48:26  Show Profile  Reply with Quote
Last few tweaks to the main frame. I'm committing this one to metal.

I laid the HT back 4 degrees to increase the trail to 2.5". It also had the effect of taking ~3" of main tube out of the frame. 1.5" of tube, top and bottom; about 0.1lb.

I also started laying out the cable routing; thinking about internal routing as much as possible.



I'd go get the gas bottles filled and start brazing this long weekend. But, my wife says the new gas bottles are a Christmas present and she's going to wrap them. So, I have to wait until the 2-week break over Christmas/New Years :(. I guess I can at least start to dismantle the prone frame...

Edited by - ShelGame on 11/24/2015 07:15:00
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warren
human power expert

USA
6090 Posts

Posted - 11/24/2015 :  08:24:17  Show Profile  Visit warren's Homepage  Reply with Quote
Well, at least that will give you time to make nice jigs and get all your tubing fish-mouthed so it fits together well.
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shooky56
recumbent guru

USA
544 Posts

Posted - 11/24/2015 :  09:43:17  Show Profile  Reply with Quote
Tell the Mrs. you'll wrap them up at Christmas time!

Looks good, keep building.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 11/24/2015 :  09:49:28  Show Profile  Reply with Quote
quote:
Originally posted by warren

Well, at least that will give you time to make nice jigs and get all your tubing fish-mouthed so it fits together well.



Exactly. I already cut the 2 HT's and fitted the front derailleur tube to the BB.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 11/24/2015 :  17:12:37  Show Profile  Reply with Quote
Printed the frame drawing full size and laid it out on the jig table...

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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 11/26/2015 :  10:13:03  Show Profile  Reply with Quote
Cuttin' metal...




The paper tube miter template tool thing seems to work well.

The 'cleats' are 1x2 pine, cut down. They're just tall enough to hit the center of the tube. They hold very well, but still easy to remove the tubes. It helps that all of the tubes in the front of the frame are 1.5" OD now.

Edited by - ShelGame on 11/26/2015 10:15:00
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warren
human power expert

USA
6090 Posts

Posted - 11/26/2015 :  10:56:27  Show Profile  Visit warren's Homepage  Reply with Quote
Yes this cool that all the tubes, even the head tube are 1.5 inch. Makes it easier to ensure its all straight for sure.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 11/27/2015 :  14:13:54  Show Profile  Reply with Quote
Main tubes are all fitted. Not to bad if you ask me, considering I haven't done this in a few (15) years. Tomorrow or Sunday, I'll try to get the vertical braces cut.





Edited by - ShelGame on 11/27/2015 14:14:55
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 11/30/2015 :  17:52:24  Show Profile  Reply with Quote
Fork came in the mail today. It's nice!

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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 12/09/2015 :  11:00:50  Show Profile  Reply with Quote
I'm looking for a nice remote steer 'stem' like this one (the aluminum crank clamped onto the steerer tube):



Is this commercially available part? Or a one-off?
It's from this thread - http://www.recumbents.com/forums/topic.asp?TOPIC_ID=4434
(I don't know who "n/a" is/was...)

Edited by - ShelGame on 12/09/2015 12:12:04
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warren
human power expert

USA
6090 Posts

Posted - 12/09/2015 :  12:56:16  Show Profile  Visit warren's Homepage  Reply with Quote
That's a one-off built by Alan. You can cut and file an MTB stem to create a similar remote steerer.

Edited by - warren on 12/09/2015 12:59:01
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 12/09/2015 :  20:15:54  Show Profile  Reply with Quote
I do have a couple of BMX stems that can probably be cut down to make a remote steer stem.

Was also playing with a set of old TT/Triathalon bars tonight. I think they'll make a nice set of handle bars. Really needs a carbon 1-1/4" tube to mount them to. The carbon stem I plan to use with them should be here this week.



Edited by - ShelGame on 12/09/2015 20:22:26
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 12/27/2015 :  12:19:05  Show Profile  Reply with Quote
I had to order an adapter for my acetylene tank :(. So, still no brazing.

The front 'triangle' is all prepped and ready to be brazed.



I also worked on the rear upper stays. I'm laying this out as a triangle first; then it will be fitted to the front triangle as a unit. I'll do the same with the lower stays. I think it's just easier to do as much work as possible on a flat surface - especially with bent tubes like my rear stays.




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warren
human power expert

USA
6090 Posts

Posted - 12/28/2015 :  18:04:34  Show Profile  Visit warren's Homepage  Reply with Quote
Very nice, Hurry up valve adapter! How much of that are you going to be able to braze on that paper/wood surface without lighting it on fire?
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 12/28/2015 :  19:12:11  Show Profile  Reply with Quote
quote:
Originally posted by warren

Very nice, Hurry up valve adapter! How much of that are you going to be able to braze on that paper/wood surface without lighting it on fire?



Ehhh, not much. At least the surface is laminate. The paper will be gone. Fire extinguisher will be nearby.

I hope to get a couple of good tacks on each joint. Then I'll put it up in my bike stand to get at all the joints.
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alevand
human power expert

USA
2910 Posts

Posted - 12/29/2015 :  05:24:29  Show Profile  Visit alevand's Homepage  Reply with Quote
You can put layers of aluminum foil over the wood. Wire brush the joints until shiny. I use an old grinding wheel to keep the wire wheel sharp, touch it a few seconds and it brushes as good a new..

C:
Tony Levand

Edited by - alevand on 12/29/2015 05:31:01
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 01/01/2016 :  11:43:16  Show Profile  Reply with Quote
Got my MC tank adapter yesterday, got the tanks filled at the local welding supply. I should have checked the tip that came with the new torch - it's a #5 not a #2. I could have picked up the right tip while I was there yesterday. Of course they're closed today. Oh well, maybe they'll be open tomorrow.

In the meantime, I did get the regs set and built a tank rack. Needs a handle on top. Not pretty, but it'll get the job done.

Finally, I lit the torch, just to see if it all works, and it does!

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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 01/11/2016 :  17:41:31  Show Profile  Reply with Quote
My #1 and #2 welding tips showed up today. Unfortunately, so did winter. It's 13deg outside, and 27 in the garage. Too cold for me; even if the torch will heat things up a bit. It's supposed to be in the 40's this weekend. Maybe I can cut some practice parts and (finally) get to welding.

Edited by - ShelGame on 01/11/2016 17:44:46
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warren
human power expert

USA
6090 Posts

Posted - 01/11/2016 :  18:14:22  Show Profile  Visit warren's Homepage  Reply with Quote
You can't catch a break! Too cold in my garage to work out there tonight too!
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 01/11/2016 :  18:18:47  Show Profile  Reply with Quote
So much for the mild "El Nino" winter we were supposed to get...
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 01/13/2016 :  17:42:56  Show Profile  Reply with Quote
In the absence of welding, how 'bout I just post pics of the parts I've been collecting for this project?

Drivetrain:


160mm 'PowerPro' (never heard of it before) cranks:


Rans seat mount parts:


POC seat (bought on BROL, but new):


A BBM (airwolf) seatpad is on order...

Edited by - ShelGame on 01/13/2016 17:59:38
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 01/16/2016 :  12:20:23  Show Profile  Reply with Quote
I fused 2 pieces of steel today. I'll hesitate to call it welding. It's not pretty. Think the torch was too hot? Maybe too oxidizing a flame?


Edited by - ShelGame on 01/16/2016 12:24:46
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warren
human power expert

USA
6090 Posts

Posted - 01/16/2016 :  12:51:32  Show Profile  Visit warren's Homepage  Reply with Quote
Yikes, what are you using for brazing rod and flux? All that scaling shows that your tubes were really hot for a long time. I usually aim for a "neutral" flame when brazing steel. This means the inner blue cone is about 3/4" long. This works well for me, but I am not a professional welder...


Edited by - warren on 01/16/2016 13:03:09
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 01/16/2016 :  13:31:18  Show Profile  Reply with Quote
I'm trying to weld first. I have the 1 butt joint in the frame that needs to be welded. After reading and watching some videos, I think I was just too far away, and over heating everything.

This is 5/8"OD x 0.035 wall tube. My main tube is 1-1/2" 0.035 tube. If I had any spare, I'd test with that. But, I figure it's best to at least use the same wall thickness.

Attempt #2 came out much better.


Edited by - ShelGame on 01/16/2016 13:32:29
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