Day 2 involved getting into Doug’s fixture. The fixture allows you to apply your specific dimensions so you’ll get a frame that fits you. Many different components are involved to make it work. At first it was difficult to envision the how to of the design. Once I was able to add a seat and stem to the fixture it started to get into focus. Setting up the small details really makes a difference. Several secrets of framebuilding were revealed!
One thing that was getting me was the timezone change and the heat. The weather was warm and humid. Also being 3 hours off was a challenge!
After lunch we started working on our lugs. This involves lots of filing. Then when I thought I was done I had to file more, and more, and more. The amount of filing involved exceeded my expectations dramatically. There is no way around it. If you want a cheap looking frame it’s easy, don’t work your lugs! Clearly you can see bad lugs on a bike, but good lug work often goes unnoticed. Look a little closer next time and you’ll see what I mean.
First problem! Once my fixture was set up for size and angles we discovered that I wouldn’t be able to use the oversized tubing and bottom bracket lugs I had ordered. I’m building a cyclocross frame so it needs to be built with more robust tubing than a road bike. My size also helps push the frame to the stronger side! Doug had to order me a new bottom bracket lug and do a swap for two different tubes and a couple lugs. Since I had to wait until Thursday for my bottom bracket it gave me plenty of time to file and file and file on my other lugs. Proper filing technique is a skill. I was going ok but struggling to eliminate small file marks in a few tight spaces. Doug showed me a technique of filing with the sharp edge of a swiss pattern file that removes the marks instantly. It’s like magic!
Filing these two lugs to fit my headtube was a seemingly never ending chore. Using some nice tools helped speed the process along and I was able to get a nice fit. Tomorrow we’re getting into the oxy-acetylene and brazing with silver. I can’t wait!
