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Grant-53
recumbent guru

USA
544 Posts

Posted - 03/14/2016 :  14:46:29  Show Profile  Reply with Quote
Our shop processes titanium plates for Synthes medical implants. I sincerely wish you a speedy healing.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 03/18/2016 :  16:38:02  Show Profile  Reply with Quote
Went to se the Dr. yesterday. Cast comes off in 3 weeks. Then I get a splint, and hopefully back to brazing.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 04/12/2016 :  07:52:53  Show Profile  Reply with Quote
Cast came off yesterday. I hope to get back to brazing this week. My right hand is still very sore. Not the break, just from being immobilized for so long, I think.

I wasn't completely idle in my cast. I got quite a bit of filling done; left handed (mostly). Still a ways to go.



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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 04/16/2016 :  16:29:00  Show Profile  Reply with Quote
Finished the main brazing today. Just need to add the cable stops and guides for the derailleur cables and brake hoses. And the rear disk mount.

Edited by - ShelGame on 04/16/2016 16:30:17
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warren
human power expert

USA
6090 Posts

Posted - 04/17/2016 :  05:52:02  Show Profile  Visit warren's Homepage  Reply with Quote
Nice fillet work. What are you using to get the fillets so smooth? I usually don't use so much braze, but that does look nice.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 04/17/2016 :  06:35:33  Show Profile  Reply with Quote
I file down any high spots with a rat tail file 1st, then an air die grinder with a sanding drum to get it to the right shape, then I use just a bit of sandpaper wrapped around a piece of hose to smooth it out. It's very time consuming. Most of those in the pics are only after 'stage 2'.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 05/31/2016 :  07:03:45  Show Profile  Reply with Quote
Filing joints is hard work. I really need to improve my brazing skill so I don't have so much to do. Frame is mostly done. I made myself an ISO rear disk jig. Turns out the off-the-shelf ISO brake bracket from Nova isn't even close to where I need it to be. So, I made one.

At my pace, it's going to be hard to get this all finished by Waterford, but I'm trying.





Edited by - ShelGame on 05/31/2016 07:18:17
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warren
human power expert

USA
6090 Posts

Posted - 05/31/2016 :  15:11:13  Show Profile  Visit warren's Homepage  Reply with Quote
Looks fine - just get it near a couple rattle cans of your favorite color and your done!
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 06/10/2016 :  12:49:52  Show Profile  Reply with Quote
Panic just set in - I realized that Waterford is next weekend. Going to Tractor Supply tonight to get my gas bottle refilled. Closest one that does welding gas is ~30 miles away...
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Speedbiker
human power expert

USA
3744 Posts

Posted - 06/10/2016 :  14:33:55  Show Profile  Reply with Quote
You are exactly on classic hpv builder schedule.
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warren
human power expert

USA
6090 Posts

Posted - 06/10/2016 :  15:30:36  Show Profile  Visit warren's Homepage  Reply with Quote
Looking forward to seeing you there next weekend!
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Grant-53
recumbent guru

USA
544 Posts

Posted - 06/10/2016 :  20:25:39  Show Profile  Reply with Quote
Wet sand, etch it, and shoot it clear to show off those great welds.
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Zephyr
Starting Member

USA
43 Posts

Posted - 06/11/2016 :  11:01:03  Show Profile  Reply with Quote
http://www.ebay.com/itm/281912887027?_trksid=p2060353.m1438.l2649&var=580886158144&ssPageName=STRK%3AMEBIDX%3AIT

Try this fork, much cheaper at $69.00. I have 2 of them, one is on my Musashi and the other is on Zephyr. Slight difference in clearance for the disc brake. The one on Musashi can take a 140mm disc while the one on Zephyr can take 140mm or 160 mm disc.

Dave
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Balor
recumbent guru

Russia
512 Posts

Posted - 06/11/2016 :  11:14:05  Show Profile  Reply with Quote
http://aliexpress.com/item/Free-shipping-The-future-of-carbon-fiber-BMX-Bicycle-fork-20-inch-disc/32600624239.html

This one seems even better.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 06/13/2016 :  06:22:53  Show Profile  Reply with Quote
quote:
Originally posted by Speedbiker

You are exactly on classic hpv builder schedule.



Lol, afraid so. At least it's on a better schedule than my prone bike. 15 years and then abandoned. Actually. I may still use that frame, just not as a prone.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 06/13/2016 :  06:24:50  Show Profile  Reply with Quote
quote:
Originally posted by Zephyr

http://www.ebay.com/itm/281912887027?_trksid=p2060353.m1438.l2649&var=580886158144&ssPageName=STRK%3AMEBIDX%3AIT

Try this fork, much cheaper at $69.00. I have 2 of them, one is on my Musashi and the other is on Zephyr. Slight difference in clearance for the disc brake. The one on Musashi can take a 140mm disc while the one on Zephyr can take 140mm or 160 mm disc.

Dave



Nice, thanks! What's the crown to axle measurement? Looks close to mine. Most of the 20" carbon forks are actually pretty tall.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 06/13/2016 :  06:34:16  Show Profile  Reply with Quote
So, I finished up the brazing last night. Got the flux all brushed off. Still have a lot of filling to do. The brake bracket was tough for me. I do OK brazing two parts with similar thickness. But, putting the 1/8" thick brake bracket onto the 0.03" tube is a PITA.

I don't think I'll paint it before I assemble it. I'm not 100% sure I won't need to change anything. So, it will probably just get WD40'd for the first ride or two.

Don't know if I'll have it ready for next weekend. I have a late phone conference tonight, and then I have to go to Nashville tomorrow. Won't be home until late Thurs night. That leaves just Friday night to finish the frame and assemble it.

I'm definitely going to Waterford. I just probably won't have the LWB with me. I can bring a MTB, right?

To add salt to that wound, I have to go overseas for 3 weeks from July 5th. I get home on the 23rd. Same day Northbrook starts :( How hard is it to race a bike with jetlag and no riding for 3 weeks before?

Pics:



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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 06/21/2016 :  07:43:07  Show Profile  Reply with Quote
Still filling the joints in the rear triangle. Didn't even come close to making the Waterford race. Sigh - my weekend was pre-planned for me anyway; Finding Dory with the kids Saturday morning, then the carnival Saturday night, and all-day fathers day with the whole family (in-laws and out-laws). And the trip to the ER for son #2 all night Friday didn't help either. He crashed his bike and took a handlebar to the gut. CT scan confirmed he's OK. Except for the apple sized knot just above his belly button. He's still sore today.

I did bolt on the rear wheel to get a picture of where it's heading...

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PUGZCAT
recumbent enthusiast

Canada
459 Posts

Posted - 06/22/2016 :  10:57:20  Show Profile  Reply with Quote
Super nice job, so far from that discouraged day of the experiment of torch melt welding that burnt holes in the tubes.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 06/22/2016 :  11:06:16  Show Profile  Reply with Quote
quote:
Originally posted by PUGZCAT

Super nice job, so far from that discouraged day of the experiment of torch melt welding that burnt holes in the tubes.



Thanks! I was never very confident that I could make that work anyway. I was hoping to figure it out enough to make that 1 joint work. Win some, lose some.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 06/26/2016 :  12:44:36  Show Profile  Reply with Quote
Basically all done filing now. I'll do a little more before paint. Going to take it to the LBS and see if they can ream the head tube(s) and chase the BB threads.

Oh yeah, the bare frame weights 6.8lbs (with cable stays and seat rail mounts). About a pound lighter than I estimated. But, I filed a lot of brass off.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 06/26/2016 :  17:24:33  Show Profile  Reply with Quote
The LBS didn't want to touch my frame. He wasn't confident enough with the tools that he wouldn't make a mistake. He recommended Assenmachers, which is a hike, but not too bad. I'll try to take it up there next Friday.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 08/23/2016 :  09:31:30  Show Profile  Reply with Quote
Wow, no updates since June.

After my trip overseas and finishing a basement remodel, I finally got the rear seat stay brackets brazed on last weekend. I have 10+ days of vacation coming up, so I will be taking the frame up to Assenmacher's to get the HT's reamed and the BB threads cleaned up. Then assembly time. I hope to have this all done and take the maiden voyage by Labor Day.
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ShelGame
recumbent enthusiast

USA
254 Posts

Posted - 09/06/2016 :  05:04:51  Show Profile  Reply with Quote
Frame has been at Assenmacher's since the 30th. Matt needed a couple weeks to get to mine. So, hopefully this week.

How do the other homebuilders handle chasing BB threads and reaming HT's? Just buy the tools? I guess if you build enough frames it pays for itself.
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warren
human power expert

USA
6090 Posts

Posted - 09/06/2016 :  05:57:38  Show Profile  Visit warren's Homepage  Reply with Quote
I usually just take the bike to a friendly LBS.
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