Making the Frame
Tom Porter's Recumbent Bike Plans 2005/2006
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New Plans 2005 Frame Build 2005/2006    
Dual 700C Z-Frame Build 2005/2006-       Tubes    Frame    Dropouts    Stays    Final
Final Components
The last of this series is about adding the front derailleur post and braze ons to complete the bike.
This shows a jig I made to hold the front derailluer post at the proper angle to the frame for brazing. Itís made out of a couple of pieces of scrap tubing, the part that holds the post is interchangeable for various tube O.D.s. In this case the angle is 43 degrees. 
After the post has had the fishmouth made for the proper angle it is placed in the jig. The Jig tube is slightly more than Ĺ half of the tube outside diameter to hold the post.

A hose clamp is added to make sure the post will not move the heat and brazing rod is applied. Itís tacked in place so that the angle alignment can be checked for the front derailleur position.
This illustrates the alignment of the centerlines of the derailleur post and bb shell. The perfect angle will cause the two tubes to intersect. 
Now the post is tacked in place and the jig removed so that the frame can be assembled to the necessary point to check the front derailleur angle to the crankset.

Here you can see that the front derailleur is angled properly to chainring for proper shifting. 
As long as the frame is assembled might as well locate the braze ons for finishing it. Here a piece of welding rod has been clamped in the front derailleur to locate the housing stop for it and marked with a permanent marker. 
Working our way back the next is the cable-housing guide. 
Next the cable-housing stop for the rear brake is marked. 
Now for the cable housing stop for the rear derailleur. 
This locates the cable-housing stop for the rear brake 
This shows the location for the cable guide to the rear brake; these I made but you can buy guides that are the right angle. 
First the cable guides are brazed to the frame. The guide is held to frame with a spring clamp and an old spoke. This applies adequate pressure to hold the guide in place without blocking access to braze on with torch. Be sure to remove one rubber pad from clamp or youíll melt it or burn it. 
Now the rear brake-housing stop is mounted using the spring clamp and a short piece of steel rod to hold it in place. Check alignment to cable guide using welding rod. 
The top hosing guide is again positioned with a piece of welding rod and clamped in place. 
Insert photo 015 Aligning housing stop (didnít get)

This is a close up of the stop held against the frame using a short piece of steel rod and spring clamp. I got the idea for this off the internet where some guy brazed a piece of rod to a spring clamp, but why bother. 

Here the steel rod passes through the guide to hold it in place. 
Rear derailleur housing stop is done next using the welding rod to help locate it.  
This hopefully shows where the stops are located in relationship to the frame tube. They are tucked under the downtube and show they do not stick out where one might rub the inner thigh against them, ask how I know.
The front derailleur housing stop in place. I'm just using the clamp directly on it because of the odd angle, I didnít want to have to make some silly holding device; this worked just fine. 
Finish brazing the front derailleur post now when doing the stop. 
I decided to add a short piece of cable housing to route the cable from frame to rear stays, this was an odd difficult angle and would have been not easy to do.  
This show the rear derailleur housing stop using a clamp I made to hold braze-ons in place. It isnít quite right but worked fine on this initial trial. Quick-Grip makes a welding clamp but is way too heavy duty for something as delicate as bike frame braze-ons. When I get it perfected Iíll explain all about it, it is slick.
The last (yay) housing stop can be added now that the placement is known. Again using a piece of welding rod and the squeeze clamp.



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