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Diy Bike ...ideas, Suggestions, Improvements


Alex Dark

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I don't know whether having a 7000 series BB shell would create any issues with welding and stuff, but might be worth giving Ceeway a shout to get a price for an alu BB shell from them perhaps. You don't get a fancy CNC'd yoke then though so I assume that's no use :P (http://www.framebuilding.com/Aluminum%20Aluminium%20Alloy%20Titanium.htm)

Do you not have the appropriate tooling at college to thread the shell? If you do get it done, don't forget to reverse thread the driveside!

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I don't know whether having a 7000 series BB shell would create any issues with welding and stuff, but might be worth giving Ceeway a shout to get a price for an alu BB shell from them perhaps. You don't get a fancy CNC'd yoke then though so I assume that's no use :P (http://www.framebuilding.com/Aluminum%20Aluminium%20Alloy%20Titanium.htm)

Do you not have the appropriate tooling at college to thread the shell? If you do get it done, don't forget to reverse thread the driveside!

Unfortunately I have to have it in 6 series at least, probably 6082..which is a bugger really :( Cheers for the web linky though luke

Nah I'm welding the shell to the yoke anyway, coustellier style so thats no real issue to be honest :)

Not really, I mean we have the lathes but thats gonna be a bugger to get right I reckons. Haha good shout, ill remember that...

Was thinking about making my own taps from old steel BB cups....put some notches in to clear swarf? Centre it with the lathe and do it....might work ..any other suggestions?

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Shitloads of cutting fluid and lots of backing out to clear haha!

Haha might be a plan then ;) We'll see really...

I mean I'm more than happy to drop £50 on the Urban BB if I knew i could use it in a different bike...but I just cant see trials companies adopting the spanish style press fit bb system anytime soon :(

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If this frame you're building is going to be fully usable then it'd make more sense to pump in another £20 and get the BB working - you can mention the choice in your writeup but to have it open to a wider range of BBs would be much better IMO.

Yeh well i mean that is the cheaper option to be honest....its that or the urban BB...cannae decide :(

Some guy on bikeradar came up with the idea of using inserts so i could whack any bb in there....but then id have to tap the insert...hmmm

Edit: Or lathe down an old bb shell. That could slide in when cooled, and the frame heated so it'd be stuck in. Then to get it out I could heat the frame and pull it to put the Spanish style BB in....that could work.

Edited by Alex Dark
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Why not just borrow a BB tap from your friendly lbs? :)

That said they might only have thread chasing taps rather than thread cutting.

I'm gonna try ringing them on Monday I thinks , hopefully they'll actually have a thread cutting tap...but I guess we'll see :)

Just gor for a normal type BB Alex, £20 to get it tapped correctly is pretty cheap and for the added benefit of knowing that there will be BB's to fit for the foreseeable future surely makes it a more viable option for your project too?

Ye Im just gonna go for the standard MTB type now I thinks....

Cheers :)

Just an update...... chainstays / seat stays are getting rolled tomorrow to the correct profile.

Fork steerer tube has been finished

Both fork dropouts are done

Both frame dropouts are completed

Come monday, I should be able to mitre and tack the forks together.....and commence work on the actual frame jig :)

Pictures up soon of me progress for those that care.

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Update....Got the tubing rolled for the chainstays today...looks pretty cool I reckon; certainly an interesting profile :)post-11254-126842297996_thumb.jpg post-11254-12684229992_thumb.jpg

Also, here's one of the fork dropout's ....cut out on a CNC router B)post-11254-126842297011_thumb.jpg

OPinions and shizzle welcome....

Also, I need a design for the booster area...if someone could some up with something cool on paint or whatever that would be cool :) Just for the top of it, use the black below....

I mean like the deng boosters, the scoops and ridges etc that differentiate between the product ranges; that's what I want.. :) The lumpy bit at the top is designed to but into the top tube, but I'm not really happy with the shape of it...if anyone's got any ideas id be happy to hear :)

post-11254-126842342057_thumb.jpg

Edited by Alex Dark
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  • 2 weeks later...
  • 5 weeks later...

BB yolk has now been fully milled for the weight savingz ;) Still looking a little rough though, will be sanded, polished, then wet 'n' dried.

post-11254-12719573849_thumb.jpg

post-11254-127195739476_thumb.jpg

Bottom bracket shell has been professionally threaded and turned down.....still 3 slots to go in to save some weights

post-11254-127195737598_thumb.jpg

Headtube has been taper turned, internally bored and milled....still two slots to go in though.

post-11254-127195733771_thumb.jpg

post-11254-127195734725_thumb.jpg

post-11254-127195735747_thumb.jpg

Mark1 of my plastic prototype brake area :)

post-11254-127195732975_thumb.jpg

Mark2 with milled down custom magura mounts ( think Echo TR/TNN, washerless )

post-11254-127195740376_thumb.jpg

post-11254-127195744018_thumb.jpg

post-11254-127195736694_thumb.jpg

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  • 1 month later...

IT IS FINISHED....completely done,. all built and has been ridden...hard :D VIDEO BELOW :D

So, so happy with her...the back brake is amazing, and the geo easily beats my Coustellier.

soooo here's the rest of the stuff I didn't manage to update....

post-11254-069983600 1276808894_thumb.jp Right here we have the BB shell with the yoke placed on.....you can see al the cut outs and shit I put into it :) Took around 8-10 hours of machining for the both of them. Polished to satin kinda finish.

post-11254-073548000 1276809127_thumb.jp Here are the production plans for the brake area....all designed off an RB booster and later cut out on the CNC router.

post-11254-023836200 1276809290_thumb.jp Got the Top brake area actually being cut out on the CNC router

post-11254-071111800 1276809299_thumb.jp and again

post-11254-089718300 1276809270_thumb.jp See the nice shiny one and the buggered one? The nadged one is why I couldnt make those bashrings, boosters etc :( Managed to take the fked one and clean it up...handmilled it and got a nice design on her.

post-11254-072684900 1276809528_thumb.jp Here are the two plates being welded together...bits of tubing been cut for the ends and a nice crude plywood jig to hold the lot together.

post-11254-030484500 1276809721_thumb.jp Got the BB yoke welded to the shell in this picture...actually on the finished bike here :)

post-11254-086094600 1276809836_thumb.jp Downtube gusset just as it was being made, styled off the XTP2 one

post-11254-084468300 1276809875_thumb.jp One of the frame being welded together...got the brake area being supported by those science clampstand thingies.

post-11254-065123200 1276809978_thumb.jp Quick snap of the frame in the lower part of the jig with my forks.

post-11254-059739500 1276810088_thumb.jp brake all fitted here...silent but deadly...amazing hold, like a vee but with bite. BEST brake ever.

post-11254-040362300 1276810132_thumb.jp Gay fisheye of above.....

post-11254-025342400 1276810206_thumb.jp and finally.....full bike all built up and shiny :)

AS usual all comments and feedback welcome...

Geometry is lovvvely for me :)

1090 with urbans, 381 stays, 71.5 HA, 675 reach, +52 bb height, 100mm headtube.

Weight was 1.71kgs

Material was 6082 T6 ( stronger than typical 6061 by a smidge )

ALL hand-made by yours truly :)

FOR VIDEO OF MAKING AND TESTING..... CLICK HERE!!! (Y)

Cheers for everyones help...couldnt have done it without you lot :)

( ooh and project got me a distinction..wooo )

Regards, Alex Dark

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