How to Build a Bicycle Frame

So I’ve been asked, on occasion, a couple of questions regarding the building of bicycle frames. The two most common ones are:

1. Do you teach?
2. Where do I get started?

The answer to the first is a resounding “no” — I simply don’t have the time or facilities to offer an effective class. I’d also like more depth of experience, as I still find myself frequently puzzling over small issues and engaging in brainstorming to solve those issues.

In response to item #2, I will refer the “curious builder” to Lugged Bicycle Frame Construction, A Manual for the First Time Builder: Expanded Second Edition by Marc-Andre R. Chimonas, which will allow the reader to build a lugged bicycle in their garage, using a few simple tools including files, a vise, and a MAPP gas torch. (Click the image, or here, to purchase at Amazon.) By no means will this turn you into a framebuilder, but it will allow you to build a frame that you can build up into a working bike and ride regularly.

If you’re really dead-set on become a framebuilder, I’d recommend arming yourself with a copy of The Paterek Manual and finding a class or apprenticeship somewhere. (The class will be easier to find, but will cost you a few thousand dollars.) Tim Paterek’s book is the end-all, be-all bible of framebuilding, as far as I’m concerned, and a copy should reside in every framebuilder’s workshop. There are earlier editions available as a free download in PDF.

I’m also convinced that there’s a market for a book that lives somewhere between these two — something not as complex as Paterek, yet addresses more than Chimonas. I’m considering writing it, what with my abundance of free time and all. (Yes, that was sarcasm.)

The Traveling Framebuilder

As you may (or may not) know, my framebuilding is primarily done in two location — Paul Wyganowski‘s workshop (where I pay monthly rent for use of the space/equipment) and at Josh Kruck‘s, where he is kind enough to allow me to hang out and bum torch time off of him. I’ve been scraping together the cash to get out of that situation for two reasons:

1. While I love working with Paul, the rent plus the cost in wear-and-tear on my car is taking a toll on my finances.
2. While I love working with Josh, my ingrained sense of guilt (genetic, due to a Catholic parent) is taking a toll on my conscience.

Two weeks ago, I started ordering equipment. This week, I started going balls-out. I have pretty much everything I need — except oxy-acetylene tanks — to accomplish about 70% of my work at-home. And I’ll be working to fill that gap in the coming months.

This is not to say that I won’t work with them both in the future — because I totally will. They’re both awesome dudes, and I love talking framebuilding with both of them.

Thoughts

I’ve been making modifications to a frame for a local rider. The frame was built by a now-out-of-business local guy whose frames have a bit of a cult following around here. Now, I know I’m still pretty new to the building thing, and I’ve only learned the methods imparted to me by my teacher, but I was highly unimpressed with what I looked at. I’m not going to name names, of course. From my perspective the things that were done were done in the name of speeding-up production — something from a business perspective is essential.

A shortcut that compromises the lifespan of the frame, however, is unacceptable. Earlier this year, in another blog, I wrote about a fillet brazed tandem that I saw that was rotting away from the inside-out, a symptom of poor ventilation strategy. The bike I’m working on is very similar. When I return it to the owner, I’ll be discussing with him the best ways to lengthen the lifespan of his bike.

I just don’t understand why a builder would sacrifice the overall quality and lifespan of his work to save 15-30 minutes. What gives?

Weekend Update

Hello, I’m Chevy Chase. And you’re not.

In all seriousness, it was another productive weekend on the bike front.

Friday, between jobs (I currently have an office gig and a part-time gig at a bike shop), I stopped at the Active Living Bike Expo, as Paul was there, and it’d give me a chance to meet Erik Noren of Peacock Groove. I only had a couple of hours there, but I helped them set up, shot the shit, and had a good time. Erik’s a groovy cat and shared some knowledge that’ll be extremely helpful in the near future. I also discussed getting in at Minnecycle 2 this year, and he was amenable to the idea; I may end up at the “newbies table”, which I envision as being something like the pre-teen table at Thanksgiving. And I’m okay with that. I’m new to this, I’m just starting out and I gotta pay my dues.

Saturday’s shift at the bike shop was uneventful and quiet due to the weather. I left early and went home.

Sunday was good. I got up and did the Minnesota Ironman (not a triathlon, but a century ride). I opted for a shorter route as it was in the mid-40′s, windy, and pissing rain. In addition to being mildly sick (sore throat, congestion), I was experiencing some digestive problems that morning, so the ride was not all it could have been. I was cramping and grumpy within 4 miles, but I ground it out and finished, coating most of Lakeville and other surrounding suburbs with a thin layer of snot.

Once off the bike, I drove straight up to Princeton and Paul and I got to work right away. We discussed pricing models while we prepped — he shared his insights and opinions based on his experiences with framebuilding, and I shot back and asked questions based on my time working in B2C and B2B environments. It was good stuff. And we got down to work.

The 29′er needed it’s seat tube/top tube joint finished before we could install the seatstays. Got most of the way through that. The fillet was shallow in a few places and required some silver to be floated in on top of it. I suspect next weekend, we’ll be finishing that and attaching the seat stays.

Between soaking the joint of flux and working on it with the Dynafile, I did work on the commuter some more. The downtube got mitered and installed into the BB shell, a time-consuming process. Next time, I’ll check and make sure there’s no headtube twist (there shouldn’t be), and start mitering the top tube and prepping the lugs to finish out the front triangle.

Sorry for the lack of photos this time. By the time we wrapped up, both the ST/TT joint of the 29′er and the BB of the commuter were both in the soak tank and I was ready to call it a day.

No Session This Weekend

No session this weekend, as Paul’s come down with some sort of illness acquired while at NAHBS. Going to take the opportunity to work on the website’s visual layer and see if I can’t get that done.

Also, I’ve provided some feedback to the artist that’s handling the artwork for my head tube badge. Hoping to hear back on that by Monday or Tuesday.

And since temps are going to be pushing 45°F today, I think I’m going to get out for a few hours on the road bike in the morning, before I go to the gym this evening (weights, followed by an S1 workout on the trainer for 60 minutes). It’ll be good to test out the new contacts out on the road.^*

If you’re local (Minneapolis) and aren’t out on your bike sometime today, please smack yourself in the face.

* I’ve never owned contact lenses before. Seriously.