Burf's Bicycle Frame Build

[Burf86]

Hi guys!

Iv been making a 'downhill hardtail' frame for what feels like for ever now. Started March last year I think. Here is the finished article

I'll upload the making of too

 

[Burf86]

Tube notcher

I made the tube notcher first. I decided to go abrasive because I was informed that holesaws could catch thin walled tubes. Well, from what I know now, I should have gone with hole saws. Because this thing has been an absolute mission to try and make straight and accurate.
I don't actually have a good picture of the notcher (need to sort that out) but you can have this as a teaser for now. It has had much modification since this picture

 

[Burf86]

Some of the frame in the jig and the seatstays

 

[Burf86]

Frame in the jig

 

[Burf86]

Weld pics man

 

[fuff66uk]

Very impressive buddy,that notcher is a wicked piece of kit,very very neat joints

 

[Wozzaaah]

I'm sure someone will chime in and say 'you should have done this' or 'you should have done that'...but it won't be me.
Really nice looking frame that Burf, very well done.
I want one!

 

[GrahamGKD]

Lovely looking frame - what tube is it? I'm curious, do you buy the tube as a sort of 'frame set' or how do you go about it? It must be hard welding neatly into some of those corners. Very Well Done.

 

[Burf86]

the top and down tube are stock tubes. plain guage 6m lengths. Stays, bb, seat tube and head tube were from c-ways and the drop outs and gussets were lazerd from sheet. All 4130

 

[gordon stephenson]

Really great fit-up on the tubes Burf,Takes a good man to do a job like that.

 

[oz.]

Let's hope the headtube stay on this one. Will be good to see you riding it.

 

[Hog-Rider]

That's some nice welding you have done there,I take it you are a welder by trade ..

 

[TheJoker]

That's really neat work there!

And this is coming from an aspiring frame builder.

the top and down tube are stock tubes. plain guage 6m lengths. Stays, bb, seat tube and head tube were from c-ways and the drop outs and gussets were lazerd from sheet. All 4130

Some questions:
"Plain gauge"? How tick?
"c-ways"? What's that?
How did you do the drawings of the laser cut parts?
What filler did you use for the welds?
Can you tell me about the jig? What materials? Tips? Tricks?
How long did it take you to build the frame and the jig?
How much does the frame weigh?

Brilliant work!

 

[GrahamGKD]

"c-ways"? What's that?

Took me a while to find it but I think it's this place.

Some really interesting stuff on that website.

Thanks for the answers on my other questions Burf - Cheers.

 

[Engineer]

Was there any need to heat treat the frame after welding?

 

[TheJoker]

Took me a while to find it but I think it's this place.

Some really interesting stuff on that website.

Thanks! I've visited that site before, but never registered its name!

 

[TheJoker]

Was there any need to heat treat the frame after welding?

I'm interested to hear too, AFAIK, there shouldn't be any need, unless you'd want to stress relieve the frame;
http://www.weldingtipsandtricks.com/welding-4130.html

 

[Burf86]

Thanks guys!

Oz you cheeky git. ha ha. I didn't weld the head tube on that frame. It was factory, thank you very much

Tubes are 1.6mm
My designer friend did the design of the frame and gave me drawings of the tubes and things. He handled the laser cutting guys, but he works in SolidWorks if that helps anything...
Filler is A15. bog standard steel filler as far as I'm aware. No need to heat treat with this filler on stuff thinner than 3mm. Give or take a bit. If you use a matched filler you have to heat treat!
It's taken about 17 months from the month I bought my Tig welder. I had the tubes and needed to notch them, so created the notcher (I will upload up to date pics of it, promise.). Mostly in the evenings and when I could get away with it at work. Then the Jig. All the metal used was scavenged from metal destined for scrap, some bits weren't... Used a mill for the slots etc. No idea on a "frame build time" as I have been making the tools as I went long, ya know?
I didn't weigh the frame. I don't care too much about these things, but it was about the same as a DMR frame I have.

Cheers Guys

 

[TheJoker]

Brilliant! Thanks! Always interesting to hear the "behind the scenes" story not just the result. I'd love to see more pics of the notcher, the jig and any other tools you can think of.

 

[smoggyrich]

Very nice.

I want one!!!!