THE

PATEREK
MANUAL
For Bicycle Framebuilders
SUPPLEMEN TED VERSION
Written by: Tim Paterek
Photography by: Kelly Shields, Jens Gunelson, and Tim Paterek
Illustrated by: Tim Paterek
Photolabwork by: Jens Gunelson
Published by: Kermesse Distributors Inc.
464 Central Avenue Unit #2, Horsham, PA 19044 216-672-0230
ACKNOWLEDGEMENTS
Thi s book woul d not have been possi bl e wi t hout hel p f r omt he
f ol l owi ng peopl e:
Ter r y Osel l
Roy Si monson
Kel l y Shi el ds
Dr . J osephi ne Pat er ek
Gi nny Szal ai
Speci al t hanks must al so go t o:
Chr i s Kval e
Ceci l Behr i nger
J ens Gunel son
J ohn Cor bet t
St eve Fl agg
Dr . Hank Thomas Dr . J ames Col l i er
Dr . J oseph Hesse J ohn Templ e
Ron St or m Paul Spei del
Laur a Or bach Mar t y Er i ckson
Mar y Ranki n Ter r y Dobl e
Todd Mol denhauer J ay Ar neson
Susan Bur ch Har vey Pr obst
Al an Cambr onne Laur el Hedeen
Mar t ha Kennedy Bi l l Far r el l
Bi l l Lof gr en Andy Bear
The f ol l owi ng compani es wer e par t i cul ar l y hel p f ul dur i ng t he
wr i t i ng of t hi s book:
T. I . St ur mey- Ar cher of Amer i ca
Bi cycl e Resear ch
Bl ackbur n Desi gn
Handy & Har mon
New Engl and Cycl i ng Academy
I sl and Cycl e Suppl y
Pr i mo Consor i zi o
Qual i t y Bi cycl e Pr oduct s
Tr ue Temper Cycl e Pr oduct s
Shi mano Sal es Cor p.
Moder n Machi ne and Engi neer i ng
Phi l Wood
Bi nks
Dynabr ade
Henr y J ames
St r awber r y
Ten Speed Dr i ve
G. P. Wi l son
Zeus Cycl er y
East si de Qui ck Pr i nt
Sant ana Cycl es
3M
AUTHOR' S FOREWORD
Ther e ar e many t ypes of bi cycl e f r amebui l der s and
t hey can be easi l y cat egor i zed i n t he f ol l owi ng way:
1. They of f er cust omgeomet r i cal speci f i cat i ons f or
each i ndi vi dual cust omer .
2. They of f er any f r ame component s t he cust omer
r equest s. i . e. t ubi ng, l ugs, dr opout s, cr own,
shel l , et c.
3. They of f er cust omf i ni shi ng wi t h a wi de r ange of
col or choi ces.
4. They al so of f er t he cust omer t he opt i on of
bui l di ng up a compl et e bi ke wi t h any gr uppo t he
cust omer want s.
5. Each f r ameset i s i ndi vi dual l y bui l t and i s not
i n any way a mass pr oduced uni t .
I t i s my cont ent i on t hat a bui l der who meet s al l 5
of t he above cr i t er i a can be consi der ed a
"
compr ehensi ve cust ombui l der
"
. Many bui l der s wi l l
el i mi nat e t he number 2 opt i on above. They f i nd a set
of l ugs, t ubes, cr own, et c. t hat t hey l i ke and st i ck
wi t h t hem. Thi s usual l y gi ves t hei r l i ne mor e of a
l ook of cont i nui t y. However , i t i s al so t he f i r st st ep
t owar d mass pr oduct i on. These bui l der s I woul d cal l
"l i mi t ed cust ombui l der s". I n addi t i on, some bui l der s
may sever el y cur t ai l opt i ons 1 and 3 as wel l . These
bui l der s I woul d cal l
"
Quasi cust ombui l der s
"
. A
bui l der t hat of f er s none of t he above opt i ons coul d be
cal l ed a "non cust ombui l der ". I ama compr ehensi ve
cust ombui l der . Each f r ame I bui l d i s t ot al l y uni que
and t akes 25 t o 30 hour s of met i cul ous wor k t o bui l d.
I have cl ose t o 100 such f r ames on t he r oad t o dat e.
I know what wor ks and what won' t wor k i n a bi cycl e
f r ame. Knowl edge of t hi s sor t cannot be got t en out of
a book. I t must be gai ned t hr ough t r i al and er r or and
much exper i ence. I have t r i ed t he best I know how t o
suppl y as much of t hi s i nf or mat i on as possi bl e. Yet , I
can' t hope t o get acr oss t o ot her bui l der s j ust what a
j oi nt f eel s l i ke when i t i ni t i al l y gi ves dur i ng
col dset t i ng. Nor , can I easi l y convey t hose f eel i ngs
t hat
"
somet hi ng j ust i sn' t r i ght . " Books cannot r eal l y
get concept s l i ke t hese acr oss t o peopl e. However ,
books ar e st i l l t he most ef f i ci ent way t o pr ogr amt he
human mi nd and we must r el y on t hemt o do so unt i l
somet hi ng bet t er comes al ong. Ther e seems t o be an
at t i t ude t oday t hat as soon as you r ead i nf or mat i on
about some subj ect , you ar e knowl edgeabl e on t hat
subj ect . I n many i nst ances, t hi s i s ver y f ar f r omt he
t r ut h. A book i s mer el y a j umpi ng of f poi nt or
l aunchi ng pad f or gai ni ng r eal knowl edge. Readi ng a
book and not f ol l owi ng i t up wi t h some pr act i cal
exper i ence i s a dead end al l ey. What I amget t i ng at
i s - Don
'
t r ead t hi s bock and t hen pr ocl ai myour sel f ar
aut hor i t y on f r amebui l di ng. You must bui l d some f r ames
bef or e doi ng t hat . For most f r amebui l der s, t he f i r st
t en f r ames ar e a di sast er . Thi s book shoul d al l evi at e
a l ot of t hat . No doubt , i t wi l l t ake about 25 f r ames
or mor e f or most of you t o devel op a l evel of
cr edi bi l i t y. Keep one t hi ng i n mi nd; each f r ame i s
easi er t han t he one bef or e. Her e ar e a f ew i deas on
how t o keep your nose cl ean i n a car eer of
f r ame bui l di ng.
Don' t do maj or wor k wi t hout a downpayment .
Don' t do wor k on a l ow bi d.
- Don' t wor k when you' r e t i r ed or f r ust r at ed.
Don
'
t cut cor ner s.
- Ri de one of your own f r ames.
- Guar ant ee your own wor k.
Don' t wi t hhol d knowl edge f r omsomeone el se who
want s t o l ear n.
Don' t badmout h ot her bui l der s.
Bef or e goi ng on t o r ead t he book, t her e ar e some
basi c pr emi ses l ai d out wi t hi n i t . They ar e:
Si l ver br azed j oi nt s ar e super i or t o br ass.
- Col d set t i ng i s necessar y t o good f r ame al i gnment .
I nvest ment cast i ngs ar e super i or t o st ampi ngs.
But t ed t ubes ar e super i or t o pl ai n gauge t ubes.
Anot her i t emt hat shoul d be ment i oned at t hi s t i me
i s t hat t her e ar e cer t ai n di scr epanci es t hat may appear
i n t he book. Two come t o my mi nd at t hi s t i me:
1. On sever al occasi ons mock- ups had t o be set up
f or t he phot ogr apher . I f t he t ext i s r ef er r i ng
t o wor ki ng on a sur f ace pl at e and t he sur f ace
shown i s cl ear l y pl ywocd or car dboar d, pl ease
l et i t sl i p by.
2. A t echni cal manual usual l y has t he model s
wear i ng of f i ci al l ooki ng wor k cl ot hes wi t h
sl eeves r ol l ed up and f l aps on t he pocket s.
The phot os i n t hi s book wer e t aken i n t he
wi nt er i n t he upper mi dwest . My shop was
r at her col d at t he t i me so pl ease par don t he
f act t hat I al ways appear ed wi t h a sweat er on
i n t he phot ogr aphs.
Keepi ng t hese t hi ngs i n mi nd, you may now go on t o
r ead t he book. I hope t hi s book l aunches you of f t o as
sat i sf yi ng an exper i ence as t he one I have had over t he
l ast si x year s.
Thi s book i s dedi cat ed t o
Ter r y Osel l
FRAME GEOMETRY
The f ol l owi ng i s a det ai l ed descr i pt i on of bi cycl e
f r ame geomet r y. I t deal s wi t h how t o comput e angl es,
cl ear ances, and t ube l engt hs and how t hose var i abl es
wi l l af f ect t he handl i ng and r i di ng qual i t i es of a
bi ke. Thi s i nf or mat i on coul d be of use t o a
f r amebui l der desi gni ng a f r ame, a sal esper son sel l i ng a
t op qual i t y f r ame, or a cust omer buyi ng a t op qual i t y
f r ame. The i nf or mat i on t hat f ol l ows i s based on
cer t ai n st andar ds of t he i ndust r y such as; 27" or 700c
wheel di amet er , 1" di amet er t op t ube, 5 t o 8 cmof
bot t ombr acket dr op, and st andar d qui l l st yl e pedal s.
I n t he case of of f - r oad, t andem, or r ecumbant bi cycl es
t he r ul es and specs whi ch f ol l ow may have t o be
modi f i ed or br oken. I n t he case of usi ng t he f ol l owi ng
i nf or mat i on t o bui l d f r ames, a hi gh degr ee of pr eci si on
i s r equi r ed. Use of a st one sur f ace pl at e, ver ni er
hei ght gage, bevel pr ot r act or , V- bl ocks, and di al
i ndi cat or s i s hi ghl y r ecommended. I n t he case of
checki ng out one' s own bi ke f or sel f sat i sf act i on, l ess
pr eci se t ool s may be used such as; st r i ngs, st r ai ght
edges, car pent er s' l evel , and an i nexpensi ve
l evel / pr ot r act or .
1- 1
I MPORTANT:
Bef or e st ar t i ng, i t i s i mpor t ant t o not e t wo
t hi ngs; 1- Di st ances on f r ames wi l l al ways be comput ed
f r omcent er t o cent er i n t hi s book. 2- An ent i r e
bi cycl e f r ame can be br oken down i nt o r i ght t r i angl es
so t hat t he Pyt hagor ean t heor emcan be appl i ed t o f i nd
al l unknowns.
SEAT TUBE LENGTH:
Thi s i s pr obabl y t he most commonl y used i ndi cat or
t o deci de whet her a f r ame i s t he cor r ect si ze f or a
r i der . Most of t en, a r i der i s asked t o st r addl e a bi ke
and l i f t t he f r ont wheel of f t he gr ound. On a busy
Sat ur day, dur i ng t he spr i ng r ush at t he l ocal bi ke
shop, t hi s wi l l usual l y suf f i ce t o sel l a $200. 00
machi ne. But when sel l i ng a t op qual i t y f r ame or
bui l di ng a cust omf r ame, a hi gher degr ee of pr eci si on
and a hi gher l evel of cr edi bi l i t y i s necessar y. Ti ght
f i t t i ng cl ot hes or t hi ck sol ed shoes wi l l t end t o cause
gr eat er r or wi t h t hi s t echni que. For t hat r eason, I
have devel oped t he f ol l owi ng si mpl e pr ocedur e and
f or mul a t c f i gur e out seat t ube l engt h:
A =I nseaml engt h i n cent i met er s wi t h st ocki ng f eet
B =Bot t ombr acket hei ght i n cent i met er s
C =Cr ot ch Cl ear ance 4 cent i met er s f or t our i ng and
6 cent i met er s f or r aci ng
D =A- ( B+C)
E =Seat t ube angl e
F =Compl ement of angl e E
Af t er measur i ng t he r i der ' s i nseamand f i ndi ng t he
ot her var i abl es ( B & E wi l l be cover ed l at er ) , 2 si des
and t hr ee angl es wi l l be known. Wi t h t hat knowl edge,
t he Pyt hagor ean t heor umcan be appl i ed t o f i nd t he seat
t ube l engt h. The f ol l owi ng f or mul a wi l l gi ve t he seat
t ube l engt h. Al l t hat i s needed i s a hand hel d
sci ent i f i c cal cul at or :
D [ sec ( F) ] =Seat Tube Lengt h
OR:
D [ cosec ( E) ] =

=Seat Tube Lengt h

si n( E)
The f ol l owi ng di agr amshoul d cl ar i f y any quest i on
whi ch may ar i se:
1- 2
I t i s a common pr act i ce of bi cycl e sal es per sonnel
t o measur e t he seat t ube l engt h f r omt he cent er of t he
bot t ombr acket t o t he t op of t he t op t ube ( poi nt X) .
I n t he desi gni ng of bi cycl e f r ames, i t i s mor e
conveni ent and pr obabl y mor e accur at e t o measur e f r om
t he cent er of t he bot t ombr acket t o t he i nt er sect i on of
t he cent er l i nes of t he seat and t op t ubes ( poi nt Y) .
Measur i ng t o poi nt X wi l l make i t sound as t hough t he
f r ame i s l ar ger t han i f t he measur ement i s t aken at
poi nt Y. Ther e i s a di f f er ence of about 13mmbet ween
t he t wo ways of measur i ng. As l ong as t hi s di f f er ence
i s t aken i nt o account , bot h met hods ar e accept abl e.
1- 3
TOP TUBE LENGTH:
Top t ube l engt h and seat t ube l engt h go
hand- i n- hand. Ther e i sn
'
t reallya neat formula to
gi ve t op t ube l engt h because of what i s t r yi ng t o be
accompl i shed wi t h t hat measur ement . I n t he case of
smal l er bi kes, wi t h a seat t ube l engt h of about 49 cm,
t oo shor t of a t op t ube woul d gi ve f ar t oo much pedal
over l ap wi t h t he f r ont wheel . Over l ap of 2 t o 3 cm. i s
not hi ng t o wor r y about . I deal l y, no over l ap i s
pr ef er r ed whi ch i s easi l y achi eved i n bi kes wi t h seat
t ubes of 55 cmor mor e. However , i f t he t op t ube gr ows
i n l engt h at t he same r at e as t he seat t ube, a 65 cm
f r ame has such a longwheel base t hat a ver y "whi ppy"
bi ke i s t he r esul t . Hence, on smal l er bi kes, t he t op
t ube i s made l ong f or saf et y and on t al l er bi kes, t he
t op t ube i s kept shor t f or a mor e sol i d f eel i ng i n
handl i ng. The di f f er ence i n t he r i der ' s r each can be
compensat ed f or wi t h a l onger or shor t er st em. That i s
t he r eason a shor t st emi s usual l y seen on a smal l bi ke
and a l ong st emi s usual l y seen on a t al l bi ke. The
f ol l owi ng char t shows t he t op t ube l engt h t o use f or
the seat tube l engt h bei ng used:
S.T. T.T.
LENGTH LENGTH
49. 5 cm 51. 5 cm
51. 0 52. 7
52. 0 53. 8
53. 0 54. 3
54. 0 54. 7
55. 0 55. 4
56. 0 56. 1
57. 0 56. 7
S. T. T. T.
LENGTH LENGTH
58. 0 cm 57. 3 cm
59. 0 57. 9
60. 0 58. 5
61. 0 59. 1
62. 0 59. 5
63. 0 60. 1
64. 0 60. 5
65 & up 60. 8
The f i gur es i n t he char t can be al t er ed a
cent i met er i n each di r ect i on and a ver y r i deabl e bi kf
wi l l r esul t . Some r i der s may r equest a r adi cal
var i at i on f r omt hi s char t due t o an ext r emel y shor t or
l ong t or so i n r el at i on t o t he l egs or due t o ext r emel y
l ong or shor t ar ms i n r el at i on t o t he r est of t he body.
I f t he di f f er ence cannot be compensat ed f or i n st en
l engt h, t hen modi f i cat i ons i n t he above char t becomes
necessar y.
I t shoul d be ment i oned her e t hat t he l engt h of t he
t op t ube can be al t er ed a cent i met er or more ineach
di r ect i on whi l e keepingt he wheel base t he same. Thi s
can be done by al t er i ng t he seat t ube and head t ube
angl es and at t he same t i me, changi ng t he r ake t o mat ch
t he new head angl e.
STEM LENGTH:
A comf or t abl e bal ance bet ween st eml engt h and top
t ube l engt h i s necessar y. I f t he f r ame i s pr ebui l t ,
1- 4
pi cki ng a st emi s easy. I f t he f r ame i s goi ng t o be
bui l t f or t he r i der , t hen t op t ube l engt h and st em
l engt h must be j uggl ed. By t aki ng t he measur ement of 1
cubi t ( t he di st ance f r omt he r i der ' s el bow t o t he
f i nger t i ps) and super i mposi ng t hi s ont o a f ul l si ze
dr awi ng of t he bi ke t o be bui l t , t he st eml engt h can be
f ound.
The f ol l owi ng di agr ams shoul d hel p cl ar i f y
t hi s:
The comf or t r ange f or most r i der s wi l l be t o have
t he f i nger t i p of t he mi ddl e f i nger f al l 0 t o 25
mi l l i met er s behi nd t he back sur f ace of t he handl ebar s.
Gener al l y a r acer or a t al l er per son may want t o go f or
25mmand a t our i st or shor t er per son may want t o go f or
t he 0 measur ement .
To f ur t her check f or t he cor r ect di st ance f r omt he
saddl e t o t he bar s, t he r i der can mount t he bi ke.
Whi l e si t t i ng on t he saddl e and hands gr i ppi ng t he
dr ops, a pl umb l i ne can be dr opped f r omt he br i dge of
t he nose. Thi s ver t i cal l i ne shoul d f al l appr oxi mat el y
i n t he cent er of t he bar t o be i n t he comf or t r ange.
STEM LENGTH AND TOP TUBE LENGTH
The combi nat i on of st eml engt h and t op t ube l engt h
can be comput ed by a si mpl e f or mul a. Not e i n t he
i l l ust r at i on how t o f i nd t he t or so measur ement ( TM) and
t he ar mmeasur ement ( AM) . The f or mul a i s ver y si mpl e:
1- 5
TM +AM
2. 3
Thi s wi l l gi ve a st ar t i ng poi nt t o wor k f r om. By
usi ng a combi nat i on of t he seat / t op t ube l engt h char t ,
t he cubi t met hod, t he above ment i oned f or mul a, and
r i der pr ef er ence, a happy medi umshoul d be abl e t o be
f ound. Keep i n mi nd t hat al l of t hese met hods onl y
gi ve st ar t i ng poi nt s f r omwhi ch t o wor k and shoul d not
be consi der ed absol ut es.
CRANK LENGTH/ SEAT TUBE ANGLE/ FORE & AFT SADDLE
ADJ USTMENT RELATI ONSHI P
Thi s i s a del i cat e ar r angement and when set up
cor r ect l y wi l l gi ve t he r i der a pr oper power st r oke.
Wi t h t he cr anks i n a hor i zont al posi t i on, f eet i n t oe
cl i ps, and r i der on dr ops - a pl umb l i ne can be dr opped
f r omj ust bel ow t he r i der ' s knee. I f al l adj ust ment s
ar e cor r ect , t he pl umb l i ne wi l l dr op t hr ough t he bal l
of t he f oot and t he cent er of t he pedal . For mor e
i nf or mat i on of si zi ng, see The New Engl and Cycl i ng
Academy - THE FI T KI T i n t he r esour ce l i st i n t he back
of t he book.
1- 6
ill 9. accommodating thigh length
STEERI NG GEOMETRY:
St eer i ng geomet r y i s ver y compl ex and was not
r eal l y under st ood f or many year s. Not unt i l our bi ke
boom, comput er i zed soci et y and hi gh t ech wor l d di d
peopl e st ar t t o r esear ch out why bi cycl es st eer ed t he
way t hey di d. For decades bi cycl es wer e bui l t by t r i al
and er r or . Peopl e di dn' t r eal l y know why some bi kes
st eer ed poor l y and ot her s handl ed wel l . But , when t hey
hi t on a bi ke t hat wor ked, t hey st uck wi t h i t . Today
we know t hat t he car ef ul bal ance of t he head t ube angl e
and t he f or k r ake wi l l gi ve us a measur ement cal l ed
"
t r ai l
"
. I t i s t hi s t r ai l measur ement t hat bui l der s of
decades ago wer e st r i vi ng f or wi t hout knowi ng i t .
HEAD TUBE ANGLE:
Thi s i s t he measur ement of f t he hor i zont al pl ane
t hat t he head t ube si t s at . Head t ube angl es usual l y
occur i n t he nar r ow r ange of 70 t o 75 degr ees wi t h
anyt hi ng mor e or l ess bei ng r at her undesi r abl e. The
head t ube angl e must be mat ched t o t he amount of r ake
on t he f or k t o pr oduce a bi ke wi t h desi r abl e handl i ng.
Head t ube angl es i n t he l ower r anges ( 70 t o 72
degr ees) ar e consi der ed t o be good f or of f - r oad use or
t our i ng. They pr oduce a sof t er r i de and a mor e
r esi l i ent f r ont end. Head t ubes i n t he mi d- r ange ( 73
degr ees) ar e consi der ed t o be good f or gener al pur pose
or spor t / t our i ng. Head t ube angl es i n t he upper r ange
( 74 t o 75 degr ees) ar e consi der ed t o be good f or r aci ng
because of t he st i f f f eel i ng t hey pr oduce i n t he
handl i ng. Most bi kes ar e bui l t wi t h head t ube angl es
i n 1 degr ee i ncr ement s but some bui l der s wi t h mor e
pat i ence, bet t er equi pment and a bet t er eye bui l d i n
1/ 2 degr ee i ncr ement s.
1- 7
FORK RAKE:
Thi s i s t he di st ance i n f r ont of t he head t ube
cent er l i ne t hat t he f r ont axl e wi l l set . I n si mpl e
t er ms, i t i s t he amount of of f set i n t he f or k. The
di agr ambel ow shoul d hel p expl ai n r ake bet t er :
For k r ake must be car ef ul l y mat ched t o t he head
t ube angl e t o pr oduce a bi ke wi t h desi r abl e handl i ng
char act er i st i cs. Gener al l y speaki ng, f or ks wi t h mor e
r ake ar e consi der ed bet t er f or t our i ng because of t hei r
abi l i t y t o absor b mor e r oad shock. For ks wi t h l ess
r ake ar e consi der ed bet t er f or r aci ng because of t he
mor e sensi t i ve f eel of t he r oad t hey af f or d.
TRAI L:
Tr ai l can be f ound by suppor t i ng t he bi ke on a f l at
sur f ace i n an upr i ght posi t i on f or measur i ng pur poses.
A cent er l i ne i s r un down t hr ough t he head t ube unt i l i t
hi t s t he f l at sur f ace. A ver t i cl e l i ne i s t hen dr opped
1- 8
f r omt he f r ont axl e unt i l i t hi t s t he gr ound. The
di st ance bet ween t hese 2 poi nt s on t he gr ound i s t he
t r ai l . The comf or t r ange of t r ai l i s 50 t o 70
mi l l i met er s. Beyond t hese l i mi t s i n ei t her di r ect i on
woul d be consi der ed l ess desi r abl e. The di agr amwhi ch
f ol l ows shows i n mor e det ai l how t o f i nd t r ai l :
The f ol l owi ng f or mul ae wi l l gi ve t he t r ai l i f r ake,
head angl e, and wheel r adi us ar e known:
Bot h f or mul ae can be easi l y wor ked out on a
sci ent i f i c cal cul at or . By exper i ment i ng, one can see
t hat many combi nat i ons of wheel r adi us, r ake, and head
angl e wi l l gi ve t r ai l r eadi ngs i n t he comf or t r ange.
By f ur t her checki ng one can f i nd t hat , of t en, hi ghl y
successf ul bi kes i n t he past had t r ai l r eadi ngs i n t he
comf or t r ange. Thi s was accompl i shed t hr ough t r i al and
er r or and by cont i nui ng t he manuf act ur e of somet hi ng
t hat wor ked wel l .
1- 9
SOME MI SCONCEPTI ONS ABOUT TRAI L
RI SI NG AND FALLI NG OF THE HEAD TUBE:
One t heor y i n exi st ance onl y a f ew year s ago was
t hat t he head t ube on some bi kes woul d dr op as t he
r i der t ur ned t o t he si de and ot her bi kes woul d r i se as
t he r i der t ur ned t o t he si de. And f ur t her st i l l , ot her
bi kes wer e supposed t o st ay l evel as t he r i der t ur ned
f r omsi de t o si de. The t heor y goes f ur t her t o st at e
t hat t he f i r st t ype descr i bed was har d t o keep goi ng i n
a st r ai ght l i ne, t he second was har d t o t ur n and, of
cour se, t he t hi r d was a bi ke wi t h desi r abl e
handl i ng. I n act ual i t y, al l bi kes wi l l dr op as you
t ur n t o t he si de unt i l you r each about 60 degr ees i n
your t ur ni ng, t hen t hey r i se shar pl y. Appar ent l y i t
was onl y a t heor y t hat no one di d any r esear ch on f or
qui t e a whi l e.
POSI TI VE- NEUTRAL- NEGATI VE STEERI NG
Anot her t heor y was devel oped dur i ng t he t i me t hat
knowl edge about t r ai l was st i l l bei ng f or mul at ed. Thi s
t heor y st at ed t hat bi kes wi t h l ess t han 50mmof t r ai l
wer e qui ck or ski t t i sh. Bi kes wi t h over 50mmof t r ai l
wer e sof t or sl uggi sh. And, of cour se, bi kes wi t h 50mm
of t r ai l wer e supposed t o be neut r al bi kes t hat had
i deal st eer i ng char act er i st i cs. I n act ual i t y, t r ai l i s
mor e on a cont i nuumwi t h t he comf or t r ange happeni ng t o
occur at 50mmt o 70mm.
*THE DAVI SON FORMULA:
Accor di ng t o t he Davi son f or mul a, a good handl i ng
bi ke had t o have r ake and t r ai l equal each ot her . He
even had t he f ol l owi ng f or mul a t o back hi mup:
Hi s f or mul a was cl osel y associ at ed wi t h t he r i si ng
and f al l i ng t heor y st at ed above. I n act ual i t y, t he
t heor y t hat bi kes wi t h desi r abl e handl i ng must have
r ake and t r ai l equal onl y wor ks i n a l i mi t ed number of
*A. C. Davi son was act i ve i n t he bi cycl e communi t y i n
t he mi d 1930' s.
1- 10
combi nat i ons and cannot be used t o wor k f or al l
si t uat i ons.
SEAT TUBE ANGLE:
The seat t ube angl e i s pr obabl y one of t he l ess
cr i t i cal f act or s i n f r ame geomet r y. I t i s t r ue t hat a
r i der pl aced mor e di r ect l y over t he bot t ombr acket wi l l
have a bet t er power st r oke t han one t hat i s
pl aced f ur t her back. However , sl i di ng t he saddl e
f or war d on t he r ai l s can have t he same af f ect as usi ng
a st eeper seat t ube angl e. Movi ng t he saddl e
hor i zont al l y 1cm appr oxi mat el y equal s 1 degr ee. I n
some cases a r i der may have an unusual l y l ong or shor t
t hi gh i n r el at i on t o t he r est of t he body. I n t hi s
case put t i ng t he saddl e back or usi ng a shal l ower seat
t ube angl e coul d make up f or a l onger t hi gh.
Conver sel y, movi ng t he saddl e f or war d or usi ng a
st eeper seat t ube angl e coul d make up f or a shor t er
t hi gh. Seat t ube angl es nor mal l y occur i n t he r ange of
72 t o 74 degr ees. An angl e of 73 degr ees coul d be
consi der ed aver age f or gener al pur pose use. Exceedi ng
t he 72- 74 r ange shoul d onl y be at t empt ed i n t he case of
a r i der wi t h l eg anat omy t hat i s beyond t he nor mal
r ange.
Gener al l y speaki ng, a f r amebui l der i s saf e t o bui l d
al l bi kes wi t h a seat t ube angl e of 73 degr ees. The
f ol l owi ng di agr am shows how seat t ube angl e i s
measur ed.
1- 11
ill.14: front center
FRONT CENTER:
Thi s i s t he measur ement f r omt he cent er of t he
bot t ombr acket t o t he center of the front axle. It is
t hi s measur ement t hat wi l l t el l i f t her e wi l l be
over l ap bet ween t he f r ont t i r e and the toeclip. An
i deal f r ont cent er measur ement i s ar ound 58cm. At 58cm
t her e i s usual l y no over l ap and t he bi ke st i l l has a
r el at i vel y shor t wheel base ( dependi ng on chai nst ay
l engt h) . Of cour se, i t i s har der t o mai nt ai n a f r ont
cent er of 58cmon shor t er and t al l er bi kes due t o what
has t o be done wi t h t op t ube l engt h. Bi kes wi t h a seat
t ube l engt h of 55 cmt o 58cmwi l l of t en t ur n out havi ng
a f r ont cent er of appr oxi mat el y 58cm unl ess somet hi ng
dr ast i c i s done wi t h t op t ube l engt h and head t ube
angl e. Anot her f act or t o consi der i s wei ght
di st r i but i on. Nor mal l y, 55%of a r i der ' s wei ght i s
over t he r ear wheel and 45%over t he f r ont wheel . A
shor t f r ont cent er wi l l al t er t hi s a smal l amount and
wi l l change t he r at i o t o sl i ght l y mor e wei ght over t he
f r ont wheel wher eas a l onger f r ont cent er wi l l put
sl i ght l y l ess wei ght over t he f r ont wheel . What does
t hi s say? Ther e i s a sl i ght possi bi l i t y t hat a r i der
wi t h mor e massi ve shoul der s and ar ms may have a l i t t l e
t r oubl e wi t h an ext r emel y shor t f r ont cent er and a
r i der wi t h a ver y sl i ght upper body bui l d may have a
l i t t l e t r oubl e wi t h a l onger f r ont cent er measur ement .
However , i t i s t he f eel i ng of t he aut hor t hat t hi s
mi ght be get t i ng i n t o a hai r spl i t t i ng si t uat i on and
t hat t he f r ont cent er mi ght not be t hat much wor t h
wor r yi ng about . The sket ch bel ow shows how t o measur e
f r ont cent er :
1-12
I t shoul d al so be ment i oned t hat moder at e pedal
over l ap i s not r eal l y cr i t i cal . Even wi t h si gni f i cant
pedal over l ap, t he t oe cannot come i n cont act wi t h t he
t i r e unl ess t he r i der i s maki ng a U- t ur n i n t he r oad or
at l east goi ng ver y sl ow.
BOTTOM BRACKET DROP:
Whi l e l ooki ng at a bi ke f r ame i t i s easy t o see
t hat t he cent er of t he bot t ombr acket i s l ocat ed at a
l ower hei ght t han t he cent er of t he axl es. Thi s
di f f er ence i n hei ght i s cal l ed bot t ombr acket dr op.
( Some manuf act ur er s r ef er t o i t as bot t ombr acket
hei ght . I n t hi s case, t he r ef er ence poi nt i s t he
gr ound not t he axl es) Typi cal l y bot t ombr acket dr op i s
bet ween 5cmand 8cmand most bui l der s wi l l st ay wi t hi n
a cl oser r ange st i l l ( 5. 5cmt o 7. 5cm) . Gener al l y
speaki ng, hi gh bot t ombr acket s ar e mor e desi r abl e f or
r aci ng and l ow bot t ombr acket s ar e mor e desi r abl e f or
t our i ng. *Si nce maneuver abi l i t y and cor ner i ng abi l i t y
ar e of i mpor t ance i n r aci ng, a r i der does not want a
f act or t o keep t he bi ke f r omexecut i ng a cor ner at a
cr i t i cal moment . Pedal i ng i nt o a cor ner woul d be one
such cr i t i cal moment . I f t he pedal on t he i nsi de of
t he t ur n i s down whi l e l eani ng heavi l y i nt o t he t ur n,
t he pedal coul d scr ape t he gr ound. Scr api ng t he gr ound
at such a t i me coul d be t ot al l y di sast r ous! For t hi s
r eason a hi gh bot t ombr acket i s i mpor t ant f or r aci ng
( par t i cul ar l y i n cr i t er i ums wher e maneuver abi l i t y can
mean wi nni ng or not and i n t he case of t r ack r aci ng
wher e t he angl e of t he banked t r ack can be di f f i cul t t o
j udge f or some r i der s) . A hi gh bot t ombr acket can
al l ow a r acer t o l ean 1 or 2 degr ees mor e whi l e
cor ner i ng ( A shor t er set of cr anks woul d al so al l ow
t hi s) . Si nce a t our i st does not have t o wor r y as much
about maneuver abi l i t y, a hi gh bot t ombr acket i s not
necessar y. Tour i st s usual l y go at a mor e r el axed pace
and whi l e execut i ng a cor ner , have t i me t o posi t i on t he
i nsi de pedal i n an upwar d posi t i on. Thi s bei ng t he
case, scr api ng pedal s shoul d al most never occur whi l e
t our i ng. On t he ot her hand, a t our i st may even desi r e
a l ower bot t ombr acket . A l ower bot t ombr acket woul d
l ower t he l oad on t he bi ke by as much as 2cmand hence,
l ower t he cent er of gr avi t y si gni f i cant l y. Thi s woul d
pr oduce a mor e st abl e bi ke t hat woul d "cr ui se" down t he
r oad mor e comf or t abl y. Aver age bot t ombr acket dr op
coul d be consi der ed t o be 7cmand a bui l der coul d be
saf e i n bui l di ng most bi kes wi t h t hat amount of dr op.
The di agr amf ol l owi ng shows how bot t ombr acket dr op i s
measur ed:
*Cr i t er i umand t r ack bi kes shoul d be bui l t wi t h hi gh
bot t ombr acket s. Bi kes used f or l ong r oad r aces, t i me
t r i al i ng and t our i ng shoul d have l ow bot t ombr acket s.
1- 13
111.15bottombracket drop
ADVANTAGES DI SADVANTAGES
CHAI NSTAY LENGTH:
Chai nst ay l engt h i s measur ed f r omt he cent er of t he
bot t ombr acket t o t he cent er of t he r ear axl e and t he
r ange i s usual l y f r om40cmt o 47cm. Typi cal l y shor t
chai nst ays ar e seen on r aci ng f r ames and l ong
chai nst ays ar e seen on t our i ng bi kes. I n f i gur i ng
chai nst ay l engt h, t hi ngs ar e not cr i t i cal when usi ng
l onger st ays f or t our i ng. However , a bui l der must be
car ef ul when bui l di ng racingframes withshort stays.
Some f r ames have such shor t st ays t hat onl y l ow pr of i l e
si l k sew- ups can be used f or t wo r easons; 1- The t i r e
mi ght hi t t he backsi de of t he f r ont der ai l l eur cl amp,
2- I f not usi ng ver t i cal dr opout s, t he t i r e may have t o
be def l at ed t o i nst al l or r emove t he wheel .
The f ol l owi ng br eakdown of advant ages and
di sadvant ages of l ong and shor t chai nst ays f or r aci ng
and t our i ng shoul d hel p t he r eader under st and t hi s
var i abl e bet t er .
SHORT
STAYS
Shorter bike for bet t er
maneuver abi l i t y
par t i cul ar l y i n a cl ose
pack of r i der s.
Less ener gy l ost i n
f r ame f l ex. A ver y
smal l wei ght savi ngs
can be not i ced.
Bet t er f or cl i mbi ng
st eep gr ades.
Wheel r emoval and
i nst al l at i on can be
hamper ed wi t h r eal l y
shor t st ays.
Oval ed or cr i mped
st ays absol ut el y
necessar y f or si de- t o
si de t i r e cl ear ance.
Pr obl ems wi t h cr oss-
over gear s ar e
accent uat ed.
1- 14
ill.16:chainstay length
ADVANTAGES DI SADVANTAGES
Use of wi de r at i o
t r i pl es i s al most out
of t he quest i on.
Di ssi pat es r oad shock
poor l y.
LONG
STAYS
Less t r oubl e wi t h
cr oss- over gear s.
Absor bs r oad shock
wel l . Handl es wi de
r at i o t r i pl es wel l .
Al l ows r oomf or use of
f ender s. Tr acks wel l
on t he r oad. Wei ght
spr ead over gr eat er
ar ea bet t er f or
l oadi ng.
Makes bi ke l ong and
"whi ppy
"
. Adds a ver y
smal l amount of
wei ght . Some ener gy
l oss due t o f r ame
f l ex. Poor maneuver -
abi l i t y.
The f ol l owi ng di agr amshows how chai nst ay l engt h i s
measur ed:
TIRE CLEARANCE:
Thi s i s t he amount of cl ear ance bet ween t he t op of
t he t i r e and t he bot t omsi de of t he cr own i n f r ont and
t he cl ear ance bet ween t he t i r e and t he br i dges i n t he
r ear . Thi s has no ef f ect on t he handl i ng of t he bi ke
unl ess a l onger f or k r epl aces a shor t er f or k or
vi ce- ver sa. I n t hat case, al t er i ng t he hei ght of t he
1- 15
head t ube can change t he head t ube angl e. Rai si ng or
l ower i ng t he head t ube mcan al t er t he angl e by
appr oxi mat el y 1 degr ee. A l ar ge amount of t i r e
cl ear ance woul d be necessar y f or t he use of f ender s
and/ or expedi t i on t i r es. Thi s woul d pr ecl ude t he use
of shor t r each br akes. On t he ot her hand, a smal l
amount of t i r e cl ear ance woul d be necessar y i n or der t o
use shor t r each br akes whi ch woul d el i mi nat e t he use of
f ender s ( AGC br akes have t he shor t est r each on t he
mar ket and may even el i mi nat e t he f ut ur e use of
st andar d shor t r each br akes!) .
TOP TUBE ANGLE:
The t op angl e shoul d usual l y be 0 degr ees. I n
ot her wor ds, t he t op t ube shoul d usual l y l i e i n t he
hor i zont al pl ane. Onl y i n t he case of t andems and/ or
l ugl ess bui l di ng shoul d t her e be any var i at i on i n t hi s
angl e. The onl y r easons f or depar t i ng f r omt hi s angl e
on a si ngl e bi ke f r ame i s f or someone wi t h back
pr obl ems who st i l l has t he per sever ance t o r i de a bi ke
or f or a per son so shor t t hat a st andar d desi gn doesn' t
al l ow enough l engt h i n t he head t ube.
FACTORS AFFECTI NG FRONT END GEOMETRY
HEADSET LOWER STACK HEI GHT:
A maj or i t y of t he hi gh qual i t y headset s on t he
mar ket have an over al l st ack hei ght of 40mm. St ack
hei ght i s si mpl y how much r oomt he headset wi l l use up
on t he st eer i ng col umn. The amount of st ack hei ght
avai l abl e on a f r ameset can be f i gur ed out as f ol l ows;
( l engt h of st eer i ng col umn i n mi l l i met er s) - ( l engt h of
head t ube i n mi l l i met er s) . The l ower por t i on of t hese
headset s have a st ack of 14mmout of t hat t ot al of
40mm. Some headset s have st ack hei ght s of 35mmor l ess
and of cour se, t hat l ower st ack hei ght i s al so l ess.
( Tange- Aer o, and Campagnol o- Gr an Spor t ar e headset s
wi t h shor t st ack hei ght s. ) I f goi ng f r oma hi gh qual i t y
headset wi t h a st ack hei ght of 40mmt o a shor t er st ack
hei ght , t he head t ube coul d dr op 3 t o 4mmThi s coul d
al t er t he head t ube angl e al most 1/ 4 degr ee. Why
anyone woul d do such a dast ar dl y t hi ng, i s unknowabl e!
( I t i s wor t h ment i oni ng her e t hat t he above ment i oned
headset s can be used on f r ameset s t hat ar e shor t of
r oomf or a highqual i t y headset . ) Headset s with40mm
st ack hei ght s ar e Campagnol o NR & SR, Speci al i zed,
Zeus, Shi mano Dur a- Ace & Dur a- Ace EX, Spi del , Avocet ,
and Chr i s Ki ng.
REPLACI NG A FORK WI TH ANOTHER WI TH DI FFERENT CLEARANCE:
I t i s i mpor t ant when buyi ng or bui l di ng a
r epl acement f or k, t hat t he same amount of cl ear ance i s
mai nt ai ned. Al t er i ng t hat t i r e cl ear ance wi l l r ai se or
1- 16
l ower t he head t ube as much as 1cmi n some cases.
REPLACI NG A CROWN WI TH DI FFERENT THI CKNESS:
The t hi ckness of a cr own i s measur ed f r omt he cr own
r ace seat t o t he under si de of t he cr own. Some of t he
t al l er cr owns, l i ke Henr y J ames, measur e 19 t o 20mm.
Some of t he shor t er cr owns, l i ke Zeus measur e 16 t o
17mm. I n bui l di ng or buyi ng a r epl acement f or k, t hat
measur ement shoul d be mai nt ai ned or compensat ed f or vi a
t he t i r e cl ear ance. An al t er at i on her e can r esul t i n
an er r or of 3 or 4mm. The di agr ambel ow shows mor e
cl ear l y what f or k cr own t hi ckness i s:
HEAD TUBE/ DOWN TUBE I NTERCEPT POI NT:
( Of f r amebui l der ' s concer n onl y)
I n bui l di ng a f r ame f r omt he f ul l si ze wor ki ng
dr awi ng, t he same bot t omhead l ug must be used as t he
one depi ct ed i n t he dr awi ng. Some bot t omhead l ugs
have t he bot t omof t he down t ube i nt er cept i ng t he back
of t he head t ube r at her l ow ( Ci nel l i - about 2 or 3mm
above t he bot t omof t he head t ube) . Ot her s ar e hi gher
at t hat poi nt ( Henr y J ames - About 9 t o 10mm) . Thi s
can r esul t i n an er r or of 5 t o 7mm. See t he di agr am
bel ow:
REPLACI NG A FORK WI TH ONE OF DI FFERENT RAKE:
When bui l di ng or buyi ng a r epl acement f or k, i t
shoul d go wi t hout sayi ng t hat a var i at i on i n t he amount
of r ake bet ween t he t wo f or ks coul d af f ect t he handl i ng
of t he bi ke dr ast i cal l y. Al ways r epl ace wi t h or i gi nal
equi pment or bui l d r epl acement par t s t o or i gi nal specs.
1- 17
RUNNI NG A DI FFERENT SI ZED TI RE ON THE FRONT:
Usi ng a 700c on t he f r ont whi l e havi ng a 27
"
on t he
r ear or vi cever sa wi l l have a mi nut e ef f ect on t he
angl e at whi ch t he head t ube si t s. Even changi ng t he
si ze of bot h wheel s at once wi l l af f ect t r ai l a smal l
amount .
STRESSI NG A POI NT:
I t i s r at her obvi ous t hat , i n t he 6 pr evi ous
subheadi ngs, t he amount of er r or was mi nut e - i n each
case. But , consi der t hi s possi bl e ser i es of event s
whi ch f ol l ow:
A bui l der desi gns a bi ke wi t h Henr y J ames l ugs and
cr own but f i nds out t hat t he l ug set s wi l l not be
avai l abl e f or 2 weeks. Si nce he i s on a t i ght
schedul e, he opt s f or a Ci nel l i set but does not bot her
t o change t he dr awi ng. Si nce t he f or k cr own was
avai l abl e, he deci des t o use t hat . Si x mont hs l at er
t he cust omer comes back af t er a bi ke acci dent . The
f or k i s r ui ned but , t he f r ame i s undamaged. The
bui l der says t hat he i s out of Henr y J ames cr owns but ,
he has some r eal l y ni ce Zeus 2000 cr owns. The cust omer
goes al ong wi t h t hat and t hen adds t hat he i s no l onger
goi ng t o use f ender s and r egul ar r each br akes and coul d
t he bui l der set t he new f or k up f or AGC br akes? The
bui l der says t hat woul d be OK and asks i f t her e i s
anyt hi ng el se. The cust omer says t hat t he r i de was
al ways t oo st i f f on t he ol d f or k and coul d t he new one
have some r ake? Of cour se, t he bui l der i s mor e t han
wi l l i ng t o obl i ge. Two weeks l at er t he f or k i s shi pped
t o t he cust omer and he t akes t he f r ame and new f or k
down t o hi s f avor i t e bi ke shop and asks t he mechani c t o
i nst al l a headset as hi s ol d one was wor n. He says
t hat t her e ar e no Campagnol o Recor d headset s avai l abl e
f or 2 weeks and woul d he set t l e f or a Campagnol o Gr an
Spor t t hi s t i me? He agr ees and when he pi cks t he bi ke
up r emember s t hat t he ol d f r ont wheel i s r ui ned.
Bef or e goi ng on t he r i de he bor r ows a 700c f r ont wheel
f r oma f r i end t o r epl ace hi s ol d 27". The t hi ng
i s so scr ewed up t hat he has anot her acci dent and wi pes
out hi s new f or k. *
That ser i es of event s was, of cour se, t he wor st
t hat coul d have bef al l en t he poor gent l eman. Fr omt he
or i gi nal dr awi ng ( whi ch we wi l l assume was
geomet r i cal l y cor r ect ) t o t he t i me t he bi ke i s r ebui l t ,
t he f r ont end has dr opped appr oxi mat el y 23mmwhi ch
woul d be appr oxi mat el y 2 degr ees st eeper on t he head
t ube. A f or k t o mat ch shoul d have been r aked l ess not
mor e. Thr ough t hi s scenar i o i t was easy t o demonst r at e
*The br and names wer e used t o st r ess a poi nt . The
qual i t y of t hose i t ems i s not i n quest i on.
1- 18
how sever al f act or s can compound i nt o a r at her l ar ge
er r or f act or . The same hol ds t r ue f or an ent i r e bi ke
f r ame. I f one smal l f act or i s sl i ght l y of f , i t may be
i mper cept i bl e. However , a whol e ser i es of f act or s
bei ng of f can make a bi ke ver y undesi r abl e or i n some
cases, near l y unr i dabl e. Thi s i s what t he r eader
shoul d be l ooki ng f or i n scr ut i ni zi ng a f r ameset . How
many f act or s hol d t r ue t o pr oper f r ame desi gn? I f some
ar e i n er r or , how many ar e t her e and what ef f ect mi ght
t hey have on t he bi ke over al l .
A WORD OF WARNI NG: Unl ess you ar e wor ki ng on a
pr eci si on gr ound sur f ace pl at e wi t h a bevel pr ot r act or ,
di al i ndi cat or s, ver ni er hei ght gage, pr eci si on hol di ng
f i xt ur es, and mai nt ai ni ng r eadi ngs of +. 005
"
- - don' t
j ump t o concl usi ons!
1- 19
FRAMEBUI LDER' S VARI ATI ONS
Thi s i s a det ai l ed descr i pt i on of sever al var i abl es
t hat can make each bi ke bui l t di f f er ent f r omanot her .
Those var i abl es can be br oken down as f ol l ows:
1 - Br aze- ons
2 - Br i dges
3 - Seat cl ust er s
4 - Lugs
5 - Bot t ombr acket s
6 - For k cr owns
7 - Dr opout s
8 - Tube set s
Consi der i ng t he choi ces wi t hi n each of t hese
var i abl es, i t i s near l y possi bl e t o bui l d an i nf i ni t e
number of t ot al l y uni que f r ame set s- - each not i ceabl y
di f f er ent f r omt he l ast . The bui l der who i s awar e of
al l of t hese var i abl es can t r ul y bui l d cust omf r ame
set s whi ch t he r i der knows someone el se wi l l not be
r i di ng. However , most bui l der s wi l l choose one or t wo
i t ems f r omeach of t he ei ght var i abl es and st i ck wi t h
t hose. Thi s l i st wi l l cover most of what can be seen
at any nat i onal bi ke show. Ther e ar e t wo ot her sour ces
f or maki ng f r ames t r ul y uni que:
1 - Check your hi st or y books, of t en t her e wer e
f i t t i ngs or embel l i shment s whi ch wer e used
decades ago t hat have been f or got t en.
2 - Your i magi nat i on.
2- 1
BRAZE- ONS:
Br aze- ons ar e smal l f i t t i ngs t hat ar e at t ached
di r ect l y t o t he f r ame by means of br azi ng or spot
wel di ng. Due t o t he f act t hat si l ver br azi ng i s t he
pr ef er r ed met hod of t he aut hor , t hi s sect i on wi l l be
wr i t t en wi t h t hat i n mi nd. By usi ng br aze- ons, i nst ead
of cl i ps, sever al t hi ngs can be accompl i shed:
1 - Use of cl i ps and br acket s can be el i mi nat ed
2 - A ver y smal l amount of wei ght can be saved
3 - A ver y cl ean l ooki ng f r ame set can be pr oduced
4 - Rust i ng and chi ppi ng whi ch occur s ar ound cl i ps
and br acket s can be near l y el i mi nat ed
5 - Equi pment whi ch coul d not be nor mal l y i nst al l ed
due t o odd t ube di amet er s can be used.
One maj or dr aw back of br aze- ons i s t hat t hey ar e
per manent l y at t ached t o t he f r ame bef or e i t i s pai nt ed.
Thi s makes i t r at her di f f i cul t t o change one' s mi nd
af t er t he wor k has been done.
WATER BOTTLE FI TTI NGS:
These ar e ver y popul ar and ar e usual l y i nst al l ed on
t he seat t ube, down t ube and t he under si de of t he down
t ube. I t ' s possi bl e t o i nst al l t hemon t he under si de
of t he t op t ube but l eakage f r omt he wat er coul d
possi bl y occur . ( On one occasi on I even saw a wat er
bot t l e mount ed t o t he head t ube. ) Ther e ar e t hr ee
maj or t ypes of wat er bot t l e f i t t i ngs. They ar e
sket ched bel ow:
The f ol l owi ng i s a l i st of possi bi l i t i es f or
l ocat i ng wat er bot t l e f i t t i ngs and pr obl ems whi ch coul d
occur by choosi ng a poor l ocat i on:
1 - The most popul ar l ocat i on f or a bot t l e i s mi d
down t ube.
2 - I f a bot t l e i s mount ed t oo hi gh on t he seat
t ube, t he r i der coul d have a di f f i cul t t i me
pul l i ng t he bot t l e out past t he t op t ube. Thi s
can be a possi bl e pr obl emon smal l f r ames.
3 - I f a pump i s mount ed under t he t op t ube, make
sur e t he bot t l e wi l l squeeze past t he pump when
2- 2
i t ' s i n pl ace.
4 - I f mount i ng a bot t l e under t he down t ube, make
sur e i t i s mount ed l ow so t hat i t wi l l not
i nt er f er e wi t h t he f r ont t i r e or f ender .
5 - When mount i ng t wo i nl i ne bot t l es on t he down
t ube, make sur e t her e i s enough cl ear ance t o
pul l t he l ower bot t l e out past t he upper one.
( Thi s pr obl emdoes not exi st wi t h Vel cr o
mount ed bot t l es. )
6 - When mount i ng t wo i nl i ne bot t l es on t he down
t ube, make sur e t her e i s enough r oomf or t he
upper bot t l e t o be pul l ed out when bot h shi f t
l ever s ar e pul l ed al l t he way back. ( Thi s
pr obl emdoesn
'
t occur when usi ng Bar cons or
st emmount ed shi f t er s. )
7 - Make sur e nei t her of t he hol es dr i l l ed f or t he
f i t t i ngs ar e sl i ght l y r ot at ed ar ound t he t ube.
Thi s woul d make t he cage si t r at her askew.
8 - Near l y al l wat er bot t l e f i t t i ngs go i nt o a 1/ 4"
hol e.
9 - Near l y al l wat er bot t l e f i t t i ngs shoul d be
spaced 63mm( 2 1/ 2") on cent er s. ( A f ew of t he
ol der Eur opean cages wer e set up f or 65mm, but
t he hol es i n t hose cages can easi l y be
el ongat ed t o f i t t he 63mmpat t er n. )
10 - Don' t mount a seat t ube wat er bot t l e l ow
enough t o i nt er f er e wi t h t he smoot h oper at i on
of t he f r ont der ai l l eur .
BRAZED- ON FRONT DERAI LLEUR:
A l i mi t ed sel ect i on of f r ont der ai l l eur s ar e
avai l abl e i n a br azed- on model . Two of t he most
popul ar ar e Campagnol o and Dur a- Ace EX. ( Ther e i s a
br azed- on Si mpl ex t hat i s not wi del y used. ) Gener al l y
speaki ng, t hese der ai l l eur s ar e f or a cl ose r at i o set
of gear s such as t hose f ound on r aci ng bi kes. They
wi l l not wor k wel l f or wi de r at i o gear i ng f or t hr ee
r easons; 1 - t he cage i s not l ong enough and t he chai n
wi l l dr ag on t he bot t omof t he cage whi l e a "gr anny"
gear i s bei ng used, 2 - The i nner cage pl at e i s not
wi de enough t o ef f i ci ent l y l i f t t he chai n of f of a ver y
smal l i nner spr ocket and i nt o t he mi ddl e posi t i on, 3 -
These der ai l l eur s do not hug t he seat t ube l i ke a good
wi de r at i o- t r i pl e one wi l l . Bel ow ar e exampl es of t he
t hr ee f i t t i ngs t o br aze- on t o use t hese der ai l l eur s:
2- 3
Her e ar e some suggest i ons f or pr oper l ocat i on and
i nst al l at i on of t hese f i t t i ngs:
1 - The t hr ee f i t t i ngs ar e not i nt er changeabl e.
2 - The Shi mano i s by f ar , t he easiest to i nst al l .
I t i s a cast i ng t hat has suf f i ci ent sur f ace
ar ea so t hat i t doesn' t need t o be hel d i n an
i nt r i cat e manner .
3 - The Campagnol o i s har der t o i nst al l . I t i s a
st ampi ng t hat must be hel d exact l y whi l e si l ver
br azi ng. SRC sells a jigto hol d t hemi n
pl ace dur i ng br azi ng.
4 - The Campagnol o f i t t i ng has t o be cocked back a
coupl e of degr ees or t he t ai l of t he der ai l l eur
cage wi l l si t t oo hi gh.
5 - These f i t t i ngs shoul d be checked f or l ocat i on
by i nst al l i ng a cr ank set and derailleur after
si l ver br azi ng. ( NOTE: Wai t f or t he f i t t i ng
t o cool bef or e i nst al l i ng t he der ai l l eur !)
6 - The Shi mano has more
"
swivel
"
adj ust ment .
7 - Unl ess speci f i ed di f f er ent l y by t he r i der , i t
is best to set the derailleur t o be i n t he
mi ddl e of i t s adj ust ment whi l e usi ng a 52 t oot h
chai nwheel .
SHI FT LEVER BOSSES:
Ther e ar e t hr ee popul ar l ever bosses on t he mar ket .
They ar e Campagnol o, Shi mano and Zeus. Any of t hemcan
be modi f i ed t o doubl e as a cabl e st op so t hat Bar cons
or st emshi f t er s can be used. The dr awi ngs bel ow show
t hemi n det ai l :
Some compani es have a l i t t l e squar e br aze- on t hat
si t s on t op of t he down t ube. Thi s al l ows t he mount i ng
of Aer o st yl e l ever s. Sunt our makes one and a separ at e
company makes one t o accommodat e Campagnol o l ever s i n
t hi s manner .
Her e ar e some suggest i ons f or mount i ng l ever
bosses:
1 - Lever bosses shoul d be mount ed so t hat t he
cent er poi nt of t he boss i s 10- 13cmdown f r om
t he poi nt at whi ch t he down t ube meet s t he head
t ube.
2- 4
2 - Campagnol o l ever bosses ar e i nt er changeabl e
wi t h Sunt our Super be, Sunt our VX, Ri no and
Si mpl ex Super L. J .
3 - Sunt our Bl uel i ne br aze- on l ever bosses ar e not
i nt er changeabl e wi t h anyt hi ng el se.
4 - Zeus br aze- on l ever bosses ar e not
i nt er changeabl e wi t h anyt hi ng el se.
5 - Make absol ut el y sur e t hat bot h l ever bosses ar e
at t he same hei ght on t he down t ube. ( Looki ng
f r omt he r i der ' s poi nt of vi ew, t hi s woul d be
ver y not i ceabl e. )
6 - Make sur e t hat nei t her l ever boss i s r ot at ed a
f ew degr ees ar ound t he t ube. ( Thi s can be
checked by si ght i ng down t he down t ube on bot h
si des at once f r oma head- on posi t i on. )
7 - See t o i t t hat a down t ube wat er bot t l e does
not i nt er f er e wi t h t he l ever s when t hey ar e
pul l ed al l t he way back.
8 - I f i nst al l i ng a set of l ever bosses on an
al r eady bui l t bi ke, make sur e t o r emove t he
cl amp st op i f one has been br azed on.
9 - Over heat i ng whi l e i nst al l i ng l ever bosses can
be devast at i ng! The down t ube i s one of t he
most heavi l y st r essed t ubes on t he bi ke.
10 - Af t er t he f l ux i s cl eaned r un a bot t omi ng t ap
i n t he bosses t o cl ean t hemout . ( Campagnol o
has 5 x . 8 met r i c t hr eads and Shi mano has 4. 5 x
. 75 met r i c t hr eads. )
CANTI LEVER BRAKE SETS:
Cant i l ever s have some advant ages over st andar d
br akes; t hey pr ovi de bi gger cl ear ances ar ound t he
wheel f or easi er i nst al l at i on of f ender s. I n t he case
of of f - r oad bi kes - - mud bui l d- up i s l ess of a pr obl em
t o t he ef f i ci ent oper at i on of t he br akes. They can be
mount ed i n numer ous l ocat i ons whi ch i s ver y
advant ageous i n t he case of t andems. Mount ai n st yl e
cant i l ever s pr ovi de much mor e l ever age and f i nal l y,
cant i l ever br akes can be r emoved and r epl aced i n ni ce
l i t t l e uni t s. Cant i l ever br aze- on st uds ar e t he same
f or al l br ands. They ar e pi ct ur ed bel ow:
ill.22cantilev er stu ds
2- 5
ifl.23: approximatecantilever locations
Her e ar e some suggest i ons and war ni ngs f or mount i ng
cant i l ever st uds:
1 - Ther e ar e t wo maj or st yl es of cant i l ever s;
shor t ones whi ch have been used f or many year s
on si ngl e bi kes, l ong ones whi ch ar e used on
mount ai n bi kes and t andems.
2 - Long cant i l ever s gi ve much mor e br aki ng power
3 - The st uds must be br azed- on at di f f er ent
hei ght s f or l ong or shor t cant i l ever s. ( See
t he di agr amt hat f ol l ows)
4 - Wheel si ze must be consi der ed when l ocat i ng
cant i l ever s.
5 - I f mount i ng cant i l ever st uds on a chr omed ar ea,
sand t hr ough t he chr ome so t hat t hey ar e
at t ached t o t he st eel under neat h.
6 - I f you onl y i nst al l a f ew cant i l ever st uds a
year , al ways assembl e t he br ake uni t and
i nst al l a wheel t o see how t hi ngs l i ne up
bef or e pai nt i ng.
7 - I nst al l i ng a r ear br ake hanger at t he same t i me
i s a good i dea.
8 - Rear st uds ar e usual l y mar ked wi t h an R or AR
and f r ont st uds ar e mar ked wi t h an F or an AV.
9 - Use of f r ont st uds on t he r ear may be r equi r ed
on shor t bi kes wi t h f ast back seat st ays.
10 - Use of r ear st uds may be r equi r ed on a mount ai n
f or k.
2-6
external
tab
The pr evi ous f i gur es ar e ver y cl ose appr oxi mat i ons.
However , i t i s st r ongl y advi sed t hat t hi ngs be
assembl ed f or f i nal checki ng bef or e pai nt i ng.
REAR RACK FI TTI NGS:
For t he most par t , t he Bl ackbur n st yl e r acks ar e
t he most pr ef er r ed t oday. Ther e ar e some l ess
expensi ve, poor er qual i t y. copi es t hat ar e made t o t he
same speci f i cat i ons. For t he sake of si mpl i ci t y, al l
t hese r acks can be l umped i nt o one bunch whi ch wi l l be
r ef er r ed t o as
"
Bl ackbur n st yl e r acks". These r acks
come i n sever al t ypes:
1 - Br aze- on mount f or shor t bi kes - - These have
ext r a l ong st r ut s goi ng t o t he seat st ays and
f i t 48- 52cmf r ames. ( Thi s i s a Bl ackbur n
C- SS- 3. )
2 - Br aze- on mount f or medi umsi zed bi kes - - These
f i t bi kes 53- 59cm( SS- 1)
3 - Br aze- on mount f or t al l bi kes - - These have
ext r a l ong and bent f or war d st r ut s goi ng t o t he
dr opout eyel et s and f i t f r ame si zes 60- 67cm.
( C- SS- 2)
4 - Br ake mount / adj ust abl e - - These f i t a wi de
r ange of si zes.
5 - Seat st ay mount / adj ust abl e ( heavy dut y) - -
These ar e pr i mar i l y desi gned f or of f r oad use
but wi l l f i t a wi de r ange of si zes.
Number s 1, 2, 3, & 5 can be mount ed on t he f r ame by
use of a br azed- on f i t t i ng. Pi ct ur es of some popul ar
st yl e f i t t i ngs can be seen bel ow:
ill. 24 rear rack braze-ons, 5X.75metric threads
Her e ar e some suggest i ons f or mount i ng car r i er
f i t t i ngs:
1 - Use f i t t i ngs wi t h 5 x . 8 met r i c t hr eads.
2 - Mount t he car r i er so t hat i t i s i n t he
hor i zont al pl ane.
3 - Don' t use t he r ack as a hol di ng devi ce whi l e
si l ver br azi ng. I t wi l l mel t !
4 - The l ocat i on f or car r i er f i t t i ngs can be f ound
by usi ng t he measur ement f r omt he cent er of t he
hol e f or t he dr opout eyel et t o t he cent er of
2- 7
ill.25 installation of external spools
LOWRI DER MOUNTS:
The use of a l ow r i der st yl e r ack can be benef i ci al
i n t hat i t l ower s t he l oad of t he f r ont panni er s by
about 6" and consequent l y l ower s t he cent er of gr avi t y.
Thi s has a st abi l i zi ng ef f ect on t he bi ke. Bel ow ar e
some met hods of i nst al l i ng br azed- on f i t t i ngs f or l ow
r i der t ype r acks:
t he hol e f or t he seat st ay car r i er f i t t i ng.
For smal l bi kes usi ng t he C- SS- 3 st yl e car r i er ,
t hi s measur ement i s 39. 5cm. For mi d r ange
bi kes usi ng an SS- 1 st yl e car r i er , t hi s
measur ement i s 39. 5cm. For t al l bi kes usi ng
t he C- SS- 2 st yl e car r i er , t hi s measur ement i s
40. 5cm. ( A smal l amount of bendi ng of t he
st r ut s may be r equi r ed when i nst al l i ng t he
car r i er . )
5 - Ext er nal br aze- ons can be hel d i n pl ace by
sl i di ng a pi ece of 1/ 8
"
st ai nl ess wel di ng r od
t hr ough t hem. ( See dr awi ng)
ill.26 low riderb raz e-ons
Her e ar e some suggest i ons f or mount i ng l ow r i der
t ype br aze- ons:
1 - The 6mmt hr eaded boss wi l l pr ovi de t he most
st r engt h.
2 - To mar k t he l ocat i on of t he br aze- ons, t he bi ke
must be l evel ed, t he r ack mount ed i n t he
dr opout hol es and t he r ack l evel ed. Then t he
l ocat i on on t he f or k bl ade may be mar ked.
Ther e i s no easy way t o l ocat e t hese br aze- ons
and have t he r ack t ur n out l evel each t i me.
Var i at i ons i n f r ont end geomet r y f r ombi ke t o
2- 8
bi ke can change t he l ocat i on of t he br aze- ons
up t o a f ul l cent i met er .
3 - Af t er t he br aze- ons ar e f i ni shed, t he r ack must
be j acked out f r omt he f or k bl ades about 1cm.
Thi s can be done easi l y by usi ng bushi ngs.
TOP TUBE CABLE GUI DES:
By i nst al l i ng t op t ube cabl e gui des, t he use of
cl i ps can be el i mi nat ed. One of t he maj or dr awbacks of
usi ng cl i ps i s t hat t hey t end t o col l ect t he
per spi r at i on t hat f al l s f r omt he r i der ' s f ace.
Consequent l y, r ust of t en occur s ar ound t he ar ea t hat
cl i ps ar e i nst al l ed. The f ol l owi ng i l l ust r at i ons show
di f f er ent st yl es of t op t ube cabl e gui des:
Her e ar e some suggest i ons f or i nst al l i ng t op t ube
cabl e gui de set s:
1 - Two cl ose l oops ar e t he st r ongest .
2 - Use a heat sync or hol d t hemby t he t ops t o
pr event over heat i ng.
3 - Locat e t he end ones about 5cmf r omt he poi nt of
t he l ugs and l ocat e t he cent er one hal f way
bet ween t he ot her t wo.
4 - Racer s may opt f or onl y t wo gui des f or wei ght
savi ngs.
5 - Si ght down t he t op of t he t op t ube t o check f or
al i gnment .
6 - The l oops ar e qui t e f r agi l e dur i ng t he si l ver
br azi ng pr ocess.
7 - Homemade gui des out of 5/ 16" x . 28" chr ome- mol y
t ubi ng wi l l accommodat e over si zed housi ng.
CABLE STOPS:
Cabl e st ops ar e pr obabl y t he most commonl y used
f i t t i ng on a bi ke. A ver y hi gh per cent age of bi kes on
t he r oad have a chai nst ay cabl e st op. Cabl e st ops can
al so be si l ver br azed on t he t op t ube f or t he r ear
br ake cabl e, at t he t op of t he down t ube f or bar cons,
at t he bot t omof t he down t ube f or gear cabl e r out i ng
or on cent er pul l br ake hanger s. Use of cabl e st ops
( and ot her br aze- ons) i s par t i cul ar l y usef ul on t andems
and mount ai n bi kes. Due t o t he over si zed t ubi ng used
2- 9
on t hese bi kes, st andar d cl i ps cannot be used. The
i l l ust r at i ons bel ow show di f f er ent st yl es of cabl e
st ops t hat ar e avai l abl e:
ill. cablestops
Her e ar e some suggest i ons f or mount i ng cabl e st ops:
1 - Mount Bar con st ops qui t e cl ose t o t he head
t ube. Thi s wi l l cut down t he amount t hat t he
cabl es r ub agai nst t he head t ube.
2 - Mount t op t ube br ake cabl e st ops al ong t he si de
of t he t ube. Mount i ng t hemon t he r i ght si de
wi l l be compat i bl e wi t h mor e br ands of br akes.
3 - When mount i ng a chai nst ay cabl e st op, r ot at e i t
out war d about 10 degr ees.
PUMP PEGS:
Usi ng a pump peg can have a coupl e of advant ages:
1 - El i mi nat i on of a cl i p i s possi bl e.
2 - The pump can be car r i ed under t he t op t ube
( wi t h cl i ps; t hi s i s di f f i cul t t o do as t op
t ubes ar e 1
"
i n di amet er and near l y al l pump
cl i ps ar e made f or 1 1/ 8") .
However , a pump peg l i mi t s you t o usi ng one si ze
and maybe even one br and of pump. Bel ow ar e some
pi ct ur es i l l ust r at i ng some di f f er ent pump pegs:
Her e ar e some suggest i ons f or i nst al l i ng a
br azed- on pump peg:
1 - I nst al l i ng a pump peg under t he t op t ube f r ees
t he ot her t ube f or use of ot her accessor i es.
2- 10
2 - I nst al l t he l ongest pump possi bl e. A l onger
pump has a bet t er compr essi on st r oke.
3 - A t i ght f i t t i ng pump wi l l have l ess t endency t o
f al l of f t he bi ke.
CLAMP STOP:
A cl amp st op i s si mpl y a l i t t l e t ab whi ch i s
usual l y br azed- on t he under si de of t he down t ube. I t
keeps a l ever cl amp f r omsl i di ng down t he t ube and a
t unnel cl i p f r omsl i di ng up t he t ube. They can be
t r i angul ar , hear t shaped, squar e or even a l i t t l e peg
st i cki ng down.
CHAI N HANGER:
A chai n hanger can he mount ed on t he i nsi de f ace of
t he r i ght seat st ay. Thi s f i t t i ng al l ows t he r i der t o
r emove t he r ear wheel and hang t he chai n on t he
chai nhanger . By doi ng t hi s t he chai n wi l l st ay on t he
chai nwheel s and r ei nst al l at i on of t he wheel i s a l ot
easi er . When t r anspor t i ng t he bi ke, t hi s al so keeps
t he chai n f r omf al l i ng of f and get t i ng gr ease al l over
t he i nt er i or of t he vehi cl e. Bel ow ar e exampl es of
di f f er ent ways t o br aze- on chai nhanger s:
Her e ar e some suggest i ons f or i nst al l i ng
chai nhanger s:
1 - The chai nhanger shoul d be l ocat ed about 6 t o
10cmabove t he r ear axl e.
2 - I f i nst al l i ng a chai nhanger on a chr omed st ay,
sand of f t he chr ome i n t hat spot as t o be
anchor ed t o t he st eel under neat h when f i ni shed.
3 - I f i nst al l i ng a chai nhanger on chr omed st ays,
mount i t a l i t t l e hi gh so t hat i t can be
pai nt ed over .
BOTTOM BRACKET GUI DES:
Bot t ombr acket cabl e gui des ar e an excel l ent way t o
el i mi nat e t he use of cabl e cl i ps. These gui des ar e
par t i cul ar l y usef ul on t andems and of f - r oad bi kes wher e
over si zed t ubi ng i s used. Bot t ombr acket gui des ar e of
t wo maj or t ypes; 1 - Topsi de gui des, 2 - Under neat h
2- 11
underneath styles
Cinelli 312/313
st yl e.
ki nds:
Bel ow ar e some pi ct ur es showi ng t he di f f er ent
Campagnolo, Shimano Cinelli
413
11: 31: bottombracket cable guides
Her e ar e some suggest i ons f or i nst al l i ng bot t om
br acket gui des:
1 - Under neat h st yl e cat ches a l ot mor e di r t .
2 - Under neat h st yl e may pr ohi bi t t he use of
cer t ai n di spl ay st ands.
3 - Under neat h st yl e may pr ohi bi t t he use of
cer t ai n exer ci se t r ai ner s.
4 - Under neat h st yl e st ands a bet t er chance of
get t i ng cr ushed or mi sshapened.
5 - Cabl es can be r out ed under t he bot t ombr acket
si mpl y by f i l i ng l i t t l e gr ooves i n t he bot t om
br acket shel l .
6 - The TREK company mount s a pl ast i c gui de pl at e
wi t h one scr ew on some model s.
7 - The TREK company has an under neat h st yl e cast
r i ght i nt o t he bot t ombr acket shel l on some
model s.
8 - A good posi t i on f or t opsi de gui des i s t o have
t he f r ont s j ust sl i ght l y bel ow t he cent er l i ne
of t he downt ube.
9 - Most hi gh qual i t y der ai l l eur s r equi r e a bot t om
br acket gui de of some sor t .
10 - Use of bot t ombr acket gui des el i mi nat es use of
cabl e housi ng ar ound t he bot t ombr acket .
11 - I t woul d be a good i dea t o r et ap and f ace t he
bot t ombr acket af t er i nst al l i ng bot t ombr acket
gui des. ( Wai t f or t he shel l t o cool !)
BARCON STOPS:
See cabl e st ops and l ever bosses on pr ecedi ng
pages.
EXTRA EYELETS FOR FENDERS:
Fi ve or Si x mi l l i met er nut s can be si l ver br azed
di r ect l y ont o t he dr opout s t o al l ow ext r a at t achment s
f or f ender s or r acks. Fol l owi ng ar e some di agr ams t o
show wher e ext r a eyel et s can be pl aced:
2- 12
piggyb ack opposing
ill.32: extra eyelets
Her e ar e some suggest i ons f or i nst al l i ng eyel et s:
1 - Fi ve mi l l i met er nut s woul d be mor e compat i bl e
wi t h t he t hi ngs t o be i nst al l ed on t he eyel et s.
2 - Af t er si l ver br azi ng t he nut on r ound t he edges
wi t h a f i l e so i t won
'
t l ook so much l i ke a
nut .
3 - The TREK company makes an eyel et t hat can be
br azed on. I t l ooks ver y much l i ke t he
or i gi nal eyel et s.
4 - I f put t i ng eyel et s on a chr omed ar ea, sand
t hr ough t he chr ome i n t he spot wher e t he eyel et
wi l l be put .
5 - Some compani es put 1/ 4
"
unt apped hol es i n t hei r
dr opout s. A wat er bot t l e f i t t i ng can be put
i nt o one of t hese hol es.
6 - Pi ggyback eyel et s ar e mor e compat i bl e wi t h a
l owr i der / f ender combi nat i on.
7 - A wat er bot t l e f i t t i ng can be put i n near t he
bot t omof t he seat st ay as an eyel et .
8 - The r ever se of an eyel et , a bol t , can al so be
br azed on t o t he f r ame.
9 - Leave enough r oombet ween eyel et s so t hat
accessor i es don
'
t r un i nt o each ot her .
BRAKE BRI DGE REI NFORCI NG SLEEVE:
Some bi kes come wi t h a si mpl e br ake br i dge t hat has
no r ei nf or ci ng sl eeve br azed i nt o i t . When t he br ake
cent er bol t i s t i ght ened down, t hi s t ype of br i dge can
col l apse and def or m. For t hi s r eason, t he br ake br i dge
hol e shoul d be dr i l l ed out l ar ge enough t o accept a
r ei nf or ci ng sl eeve. The sl eeve i s si l ver br azed i n and
t he br i dge becomes much st r onger as a r esul t .
Fol l owi ng ar e some pi ct ur es t o cl ar i f y what such a
sl eeve l ooks l i ke:
2- 13
iil.33: b roke b ridge reinforcing sleev e
Her e ar e some suggest i ons f or i nst al l i ng
r ei nf or ci ng sl eeves:
1 - Make sur e t he hol e i s dr i l l ed st r ai ght i n bot h
pl anes.
2 - Have enough cl ear ance f or si l ver t o f l ow i nt o.
3 - Make sur e t he hol e i s cent er ed al ong t he l engt h
of t he br i dge.
Mor e on br ake br i dges wi l l be cover ed i n t he next
sect i on of Fr amebui l der s' Var i at i ons.
SPOKE CARRI ER/ CHAI NSTAY GUARD:
A handy opt i on t hat i s bei ng of f er ed on many hi gh
qual i t y t our i ng bi kes t hese days i s a spoke car r i er
mount ed on t he t op of t he r i ght hand chai nst ay.
Because of i t s l ocat i on and posi t i oni ng, i t doubl es as
a chai nst ay pr ot ect or al so. They can be made t o hol d
as many as 5 spokes at once. I magi nat i on i s t he key t o
desi gni ng t hese as t hey ar e not r eadi l y avai l abl e t o
t he f r amebui l di ng mar ket yet . Her e i s an i l l ust r at i on
t o cl ar i f y what one of t hese f i t t i ngs l ooks l i ke:
Her e
car r i er :
ar e some suggest i ons f or i nst al l i ng a spoke
1 - Cabl e r out i ng shoul d be under t he bot t om
br acket i f t he spoke car r i er i s t o be mount ed
on t he r i ght chai nst ay.
2- 14
2 - Sever al spoke car r i er s may be mount ed on a
f r ame.
3 - Deci de on t he l engt h of spoke t hat wi l l f i t
bot h wheel s and spoke car r i er .
4 - The spoke car r i er shoul d be mount ed about t wo
cent i met er s i n f r ont of t he dr opout and r ot at ed
out war d about 10 degr ees t o keep i t f r om
hi t t i ng t he chai n i n t he upper gear s.
CENTER PULL HANGERS:
Mount i ng a cent er pul l hanger di r ect l y t o t he upper
por t i on of t he seat st ays t ends t o be much cl eaner and
mor e ef f i ci ent t han bol t i ng one t o t he seat l ug. Ther e
i s not t he pr obl emof t he hanger r ot at i ng when
adj ust i ng t he pi nch bol t . A hi gh qual i t y, al i en t ype
pi nch bol t can be used mor e easi l y. Ther e ar e many
ways t o set up a cent er - pul l hanger . Her e ar e t wo ways
whi ch l ook good and ar e r el at i vel y easy t o do:
Her e ar e some suggest i ons f or i nst al l i ng a
cent er - pul l hanger :
1 - Mount i t f ar enough away f r omt he br ake uni t so
t hat good l ever age i s obt ai ned but t he car r i er
cl i p does not hi t t he hanger . ( Thi s may be
di f f i cul t t o do on smal l er f r ames. )
2 - Use onl y chr ome- mol y or equi val ent t o make t he
hanger . Mi l d st eel coul d f l ex or bend under
t he l oad of br aki ng.
3 - Be sur e t hat t he hol e i n t he cent er of t he
hanger poi nt s t o a l ocat i on hal f way bet ween
t he br ake shoes.
CRESTS, EMBELLI SHMENTS AND CUTOUTS:
I n t he case of st r i vi ng f or a t ot al l y di st i nct and
uni que f r ame a bui l der can cr eat e al l t ypes of
embel l i shment s. The possi bi l i t i es ar e as l i mi t l ess as
t he bui l der ' s i magi nat i on. Her e ar e j ust a f ew i deas
f or cr est s and embel l i shment s:
2- 15
These ar e some of t he t hi ngs I have done i n t he
past . Of cour se, t he possi bi l i t i es ar e l i mi t l ess.
Thi s sor t of wor k t akes a st eady hand and a l ot of
pat i ence. The begi nni ng f r amebui l der may want t o
appr oach t hi s sor t of wor k wi t h caut i on.
2- 16
BRI DGE VARI ATI ONS
CHAI NSTAY BRI DGES:
Chai nst ay br i dges ar e of i mpor t ance f or t wo mai n
r easons; 1 - They add a not i ceabl e amount of st i f f ness
i n t he r ear t r i angl e, 2 - They pr ovi de a way t o at t ach
a r ear f ender . Anot her use whi ch i s of ver y l i t t l e
i mpor t ance i s t hat of pr ovi di ng a st op f or a ki ckst and
t o br ace agai nst . Ther e ar e sever al var i at i ons t hat
ar e possi bl e i n chai nst ay br i dges. They ar e as
f ol l ows:
STANDARD
Thi s i s t he t ype seen on most f r ames. I t i s si mpl e
and easy t o i nst al l . Si nce t her e i s no out l et f or ai r
expansi on i n t hi s t ype of br i dge, ai r expansi on hol es
must be dr i l l ed i n t he br i dge i t sel f or i n t he st ays.
STANDARD- THREADED
Usi ng a wat er bot t l e f i t t i ng i n t he back of t he
br i dge f or mount i ng f ender s i s a ni ce t ouch f or t our i ng
f r ames. The t hr eaded f i t t i ng al so ser ves as a bui l t - i n
ai r expansi on hol e. Dr i l l a second vent hol e i n t he
f r ont of t he br i dge.
STANDARD- SMALL DI AMETER
A pi ece of . 250
"
t o . 375" O. D. mat er i al can be used
t o make a smal l er di amet er br i dge. When usi ng a
smal l er di amet er l i ke t hi s, i t i s a good i dea t o use
somet hi ng wi t h a t hi cker wal l t o t r y t o gai n some
2- 17
st r engt h back. A smal l er di amet er pi ece of t ubi ng i s
not as st r ong as a l ar ger di amet er pi ece wi t h t he same
wal l t hi ckness. Ai r expansi on hol es ar e st i l l
necessar y.
U- SHAPED
A pi ece of t hi ck wal l ed . 250" O. D. t ubi ng can be
heat ed up and bent i nt o a U- shaped br i dge. Thi s woul d
wor k out bet t er on a r aci ng f r ame as f ast eni ng f ender s
t o i t woul d be r at her di f f i cul t .
CONCAVE
Sever al of t he hi gh qual i t y Eur opean bui l der s use
t hi s st yl e. i t i s at t r act i ve and, si nce i t i s
pr ef abr i cat ed, easy t o f i t and i nst al l . I t i s hol l ow
t hough and, t her ef or e, needs ai r expansi on hol es al so.
1ll.46
.
concav e
DRI LLED THROUGH
Thi s i s a r at her bol d appr oach. The f i r st
i mpr essi on i s t hat i t i s weak. However , si nce t hi s
2- 18
ill.48: no b ridge
l ar ge hol e t hr ough t he chai nst ays i s f i l l ed by t he
br i dge t ubi ng, l ost st r engt h i s added back agai n. Ai r
expansi on hol es ar e unnecessar y f or t hi s t ype of
br i dge.
NO BRI DGE
Even t hough t he br i dge i s a usef ul addi t i on i t can
be el i mi nat ed al t oget her . I f one chooses not t o use a
br i dge bet ween t he chai nst ays, i t must be r emember ed
t hat i f t he wheel i s not i n t he r ear t r i angl e a
weakness exi st s. I n t r anspor t i ng such a f r ame a dummy
axl e shoul d be kept i n t he r ear dr opout s.
BRI DGE STI FFENERS
Ther e ar e a f ew st yl es of br i dge st i f f ener s on t he
mar ket . These ar e decor at i ve pi eces t hat f i t bet ween
t he br i dge and t he chai nst ay. They do add st r engt h t o
t he j oi nt by i ncr easi ng t he sur f ace f or t he si l ver
al l oy t o occupy. However , of t en t hey ar e di f f i cul t t o
f i t because i mmedi at el y behi nd t he br i dge i s wher e
t her e i s ei t her a cr i mp i n t he chai nst ay or wher e t he
chai nst ay st ar t s i t s oval cr oss sect i on. I f i nst al l i ng
chai nst ay br i dge st i f f ener s, don' t opt t o use br ake
br i dge st i f f ener s as a subst i t ut e. They ar e t oo l ong
and bent t o a di f f er ent r adi us. Chai nst ay br i dge
st i f f ener s can be used wi t h any 1/ 2" di amet er br i dge.
2- 19
ill.50 : s tandard
ill 49: stiffeners
BRAKE BRI DGES
STANDARD - NOT REI NFORCED
Many pr oduct i on l i ne bi kes, i n or der t o cut cost s,
do not have a r ei nf or ced hol e i n t he br ake br i dge.
Thi s i s not a good i dea! Ti ght eni ng t he br ake cent er
bol t t oo t i ght can cr ush such a br i dge. No ai r
expansi on hol es ar e necessar y i n t hi s br i dge.
STANDARD- SI MPLE REI NFORCEMENT
I n or der t o el i mi nat e t he pr obl emof cr ushed
br i dges t he br ake hol e can be dr i l l ed out t o 5/ 16
"
and
a pi ece of 5/ 16" x . 028" t ubi ng can be si l ver br azed i n
pl ace. A t r ansver se ai r expansi on hol e shoul d be
dr i l l ed t hr ough t he r ei nf or ci ng sl eeve. When
assembl i ng t he br ake cal i per , r adi us bushi ngs must st i l l
be used.
2- 20
cylindrical b oss
ill.54: V-shaped
2- 21
STANDARD-FLANGED REINFORCEMENT
Pr ef abr i cat ed r ei nf or ci ng sl eeves can be pur chased
t o f i t i nt o a st andar d br ake br i dge. The pl at e or
f l ange on t he back si de al l ows t he el i mi nat i on of t he
use of r adi us bushi ngs. These al so must have a
t r ansver se ai r expansi on hol e dr i l l ed i nt o t he sl eeve.
Thi s t ype of sl eeve i s al so avai l abl e i n an al i en
st yl e.
ill.52: flanged reinforcement
STANDARD-WITH CYLINDRICAL BOSS
These have been used a l ot on Br i t i sh bi kes i n
par t i cul ar . I t i s an at t r act i ve st yl e and qui t e
st r ong. However , i t must be pr eassembl ed bef or e
i nst al l ed and posi t i oni ng of t he hol e can be somewhat
of a chal l enge. No ai r expansi on hol e i s necessar y f or
t hi s br i dge.
i l l . 53:
V-SHAPED
St andar d 1/ 2" di amet er br i dge mat er i al can be cut
and modi f i ed t o get t he ef f ect pi ct ur ed bel ow. A
f l anged r ei nf or cement must be used and ai r expansi on
hol es ar e necessar y. Thi s st yl e of br i dge i s t r ul y a
chal l enge even f or t he exper i enced f r ame bui l der .
ill.55: old style Cinelli
ill.59: Cinelli aero designs
PREFABRI CATED BRI DGES
OLD STYLE CI NELLI
I f avai l abl e, t hi s i s a f ai r l y i nexpensi ve br i dge
whi ch i s made t o accept an al i en st yl e br ake nut . A
t r ansver se ai r expansi on hol e i n t he sl eeve i s
necessar y.
NEWSTYLE CI NELLI
Thi s i s a ver y at t r act i ve pr ef abr i cat ed br i dge
whi ch accept s an al i en t ype br ake nut . I t r equi r es
pr eassembl y bef or e i nst al l i ng whi ch can pr ove a bi t of
a chal l enge f or t he begi nner . I t does not r equi r e ai r
expansi on hol es.
ill56 : Cinelli 40 6
SQUARE CENTER CI NELLI
Thi s i s a ver y easy t o i nst al l pr ef abr i cat ed br i dge
whi ch accept s an al i en t ype br ake nut . I t r equi r es no
pr eassembl y and no ai r expansi on hol es. A wor d of
war ni ng - of t en t i mes t he br ass cent er wi l l dr op out of
t hese af t er heat i s appl i ed f or si l ver br azi ng!
Anot her ver si on of t hi s br i dge has a mi nut e i mpr essi on
of a bi cycl e r i der . St i l l anot her has an i mpr essi on of
t he Ci nel l i l ogo.
ill.57: Cinelli 50 6
AERO STYLE CI NELLI
An easy t o i nst al l pr ef abr i cat ed br ake br i dge whi ch
r equi r es no pr eassembl y and no ai r expansi on hol es.
They accept an al i en t ype of br ake nut .
2- 22
SOLI D STYLE CI NELLI
Somet i mes i t
'
s har d t o be t ot al l y unbi ased. Thi s
is one of t hose t i mes. Thi s i s an easy t o i nst al l ,
pr ef abr i cat ed br i dge whi ch r equi r es no pr eassembl y and
no ai r expansi on hol es. I t accept s an al i en t ype br ake
nut and i s absol ut el y t he heavi est pi ece of br i dgi ng on
t he mar ket !
Cinelli solid
DIAMOND STIFFENERS
Di amond shaped st i f f ener s can be used on al most any
st yl e br i dge. They def i ni t el y have a st r engt heni ng
ef f ect on t he j oi nt s wher e t he br i dge meet s t he
seat st ay. The i ncr eased sur f ace ar ea i s what gi ves
t he added st r engt h. St i f f ener s shoul d be used on al l
pr ef abr i cat ed br i dges ( wi t h t he except i on of t he Aer o
and Sol i d st yl es) .
HELPFUL HI NTS
Her e ar e some hel pf ul hi nt s f or i nst al l i ng
chai nst ay and br ake br i dges:
1 - The br ake hol e must be cent er ed exact l y bet ween
t he st ays and gr eat car e must be t aken i n doi ng
t hi s.
2 - The br ake hol e must be per pendi cul ar t o t he
cent er l i ne of t he br i dge. When si ght i ng
t hr ough t he br ake hol e, you shoul d be abl e t o
si ght i n on t he cent er l i ne of t he seat t ube.
3 - Al t hough not as cr i t i cal , t he br ake hol e shoul d
be per pendi cul ar t o t he pl ane of t he seat st ays.
I f not per pendi cul ar , t he br ake cal i per wi l l be
r ot at ed sl i ght l y upwar d or downwar d.
4 - The chai nst ay and br ake br i dges shoul d be t he
same di st ance f r omt he out si de r adi us of t he
t i r e on t our i ng bi kes. Havi ng a r ear f ender
t hat doesn' t r un concent r i cal l y wi t h t he r ear
wheel l ooks pr et t y unsi ght l y.
2- 23
ill.61: standard - concav e
5 - Ai r expansi on hol es must be used when cal l ed
f or . I f t hey ar e not used, a poor j oi nt i s
pr oduced and unsi ght l y spat t er mar ks can occur .
The hol es can be dr i l l ed i nt o t he br i dge, t he
r ei nf or ci ng sl eeve, or i nt o t he st ay.
6 - I f f ender s wi l l be used, pl ai n br i dges wi t hout
an al i en t ype hol e, shoul d be used. However ,
f ender s can be mount ed on an al i en t ype br i dge
by put t i ng t he L- br acket bet ween t he br i dge and
t he cal i per .
7 - The f i t f or a br i dge must be exact and shoul d
be r at her t i ght . A sl oppy f i t or l oose f i t
wi l l t end t o dr aw t he st ays t oget her and
pr event t he wheel f r omsl i di ng easi l y i nt o
pl ace.
SEAT CLUSTERS
Thi s i s one of t he ar eas t hat a bui l der can make
t he f r ame t r ul y uni que. For exampl e, Fal con has l ong
been known f or t he st yl e of wr ap ar ound seat st ays t hey
use. Tr ek i s known f or t hei r seat st ays t hat have t hei r
name st amped i n t hem. Ral ei gh Pr of essi onal f ast back
seat st ays ar e t r ul y uni que. Ol der Ci nel l i s wer e known
f or t he way t hey i ncor por at ed t he seat post bi nder i nt o
t he t op of t he seat st ays. Unl i ke any ot her var i at i on
on t he f r ame, t he seat cl ust er can t end t o become a
t r ademar k or even a si gnat ur e f or a bui l der . Ther e ar e
a gr eat number of possi bi l i t i es f or f i ni shi ng up a seat
cl ust er . Fol l owi ng ar e about a dozen maj or ways t o do
i t . The bui l der can br anch of f f r omt her e.
STANDARD- CONCAVE
A l ar ge maj or i t y of t he f r ames on t he mar ket use
t hi s st yl e. I t i s r el at i vel y easy and i nexpensi ve t o
i o. I t can be done by t wo met hods:
1 - Fi t t i ng a pi ece of 1" di amet er t ubi ng i nt o t he
t op of t he st ays and t r i mmi ng of f t he excess.
( Thi s i s t he har d way. )
2 - I nser t pr ef abr i cat ed sl ugs i nt o t he t ops of t he
st ays.
2-24
u se of
flat stock
u se of
slu gs
ill.63partial w rap arou nd
STANDARD- FLAT
Thi s met hod i s al so used a l ot i n t he i ndust r y. I t
i s al so easy and i nexpensi ve t o do. Two met hods can
al so be done t o accompl i sh t hi s st yl e:
1 - Si l ver br azi ng a f l at pl at e ont o t he t op of t he
st ay and cl eani ng of f t he excess.
2 - I nser t pr ef abr i cat ed sl ugs i nt o t he t ops of t he
st ays. Bot h ways ar e equal l y as easy.
ill. 62: standard-flat
PARTI AL WRAP AROUND
Some bui l der s do t hi s st yl e. Ther e i s one mai n
r eason f or adopt i ng t hi s st yl e - t he i ncr eased ar ea f or
t he si l ver adds appr eci abl e st r engt h t o t he j oi nt .
FULL WRAP AROUND- FLAT
Thi s i s by f ar t he st r ongest seat cl ust er t hat can
be done. The sur f ace ar ea f or t he si l ver t o occupy i s
at a maxi mum. However , i f one i s ext r emel y wei ght
consci ous, t hi s i s al so t he heavi est seat cl ust er .
2- 25
ill. 64: full wrap around-flat
ill.65:full wrap around- round
FULL WRAP AROUND-ROUND
Thi s has t he same advant ages as t he f l at st yl e.
However , i t r equi r es t he f abr i cat i on of a speci al pi ece
t o connect t he seat st ays t oget her .
FAST BACK-WITH EAR ON LUG
Fast back seat cl ust er s have t wo advant ages:
1 - They ar e qui t e easy t o do.
2 - The open ar ea on t he si de of t he seat l ug can
be dr essed up wi t h a cut out .
The mai n di sadvant age of t hi s st yl e i s t he l ack of
st r engt h. Si nce a f ast back seat cl ust er i s t he
nar r owest par t of a bi ke f r ame, a f ai r amount of
l at er al st r engt h and st abi l i t y i s l ost . ( The
pr evi ousl y ment i oned st yl es at t ach t o t he si des of t he
seat l ug and f or t hat r eason have gr eat er st r engt h. )
2-26
modified slu gs
1167: fastb ackw ith alien b inder
These have t he same advant ages and di sadvant ages as
t he af or ement i oned cl ust er . They also have an
addi t i onal di sadvant age- - a del i cat e bal anci ng act i s
necessar y dur i ng si l ver br azi ng. The begi nni ng builder
shoul d have a f ai r amount of pr act i ce bef or e at t empt i ng
t hi s st yl e sent cl ust er .
FAST BACK- RALEI GH PRO STYLE
These have t he same st r engt h f act or disadvantage as
t he ot her f ast backs. They al so r equi r e t he use of a
Feat l ug wi t h ampl e space bel ow t he bi nder i n back.
Fur t her , some r at her f ancy mi t er i ng and del i cat e f i l l et
bui l di ng ar e r equi r ed. These shoul d be at t empt ed by
t he exper i enced f r amebui l der .
2- 27
This joint requ ires
compou nd miters
and fillet b raz ing.
Use Cinelli slu g
50 9/14 or 50 9/16.
ill 68: fastb ack- Raleigh Pro style
SEMI FAST BACK
Ci nel l i makes a pr ef abr i cat ed sl ug t hat f i t s t he
t op of t he seat st ays. They ar e machi ned out on t he
i nsi de sur f ace so t hat t he sl ugs l i e i n cl ose t o t he
si des of t he seat l ug. Thi s gi ves t he appear ance of a
seat cl ust er t hat i s nei t her st andar d nor f ast back.
ill.69: semi-fastb ack
OPEN TOP
A st andar d st yl e seat cl ust er can be assembl ed
wi t hout t he caps or sl ugs at t he t op of t he st ays.
Thi s l eaves t he t ops of t he seat st ays wi de open. Ther e
i s a subst ant i al amount of st r engt h l ost by t hi s
met hod. I t shoul d onl y be done f or ext r emel y l i ght
r i der s or f or t i me t r i al bi kes wher e wei ght i s of
ut most i mpor t ance. A dr ai n hol e shoul d al so be
pr ovi ded at t he bot t omof t he st ay as t he st ays coul d
car r y up t o 6 f l ui d ounces of wat er on a r ai ny day.
( Appr oxi mat el y 1/ 4 l b. )
2- 28
possib le prob lem area
70: opentop
RAMJET AFTERBURNER STYLE
Thi s i s r eal l y qui t e a uni que st yl e t hat wi l l make
t he f r ame st and out i n a cr owd. I t r equi r es a l ot of
modi f i cat i on of t he l ug bef or e t he f r ont t r i angl e i s
even assembl ed. Bef or e at t empt i ng t hi s st yl e seat
cl ust er , t he bui l der shoul d have devel oped some
exper t i se i n l ow t emper at ur e f i l l et br azi ng.
111.71. afterb u rner style
TEARDROP EFFECT
A l i t t l e bi t of a nub can be l ef t on t he bot t omof
t he seat st ay cap. I t can be ki nd of a ni ce l i t t l e
t ouch f or someone who l i kes det ai l wor k.
2- 29
111.72: teardrop
This is a modifi-
cation of the stan-
dard flat style.
STRESS RELIEF HOLES
Af t er t he seat cl ust er i s f ul l y assembl ed t he sl ot
shoul d be cut i n t he back of t he seat l ug bef or e t he
br ake br i dge goes i n. ( The br ake br i dge of t en becomes
an obst acl e t hat makes cut t i ng t he sl ot qui t e a chor e. )
The bot t omof t he sl ot shoul d al ways have a st r ess
r el i ef hol e. Thi s hol e wi l l gr eat l y r educe t he chances
of a ci r cul ar cr ack devel opi ng at t he bot t omof t he
sl ot . Bel ow ar e some exampl es of st r ess r el i ef hol es.
iil.73:stress relief holes
SEAT CLUSTERS NOT AVAILABLE TO THE GENERAL MARKET
Many compani es and i ndependent bui l der s have
seat st ay sl ugs and even compl et e seat cl ust er s
manuf act ur ed f or t hem. Some exampl es ar e Masi , Col nago
and Tr ek who al l have t hei r name or l ogo i ncor por at ed
i nt o t hei r seat cl ust er s. I f you want t o bui l d a f r ame
wi t h one of t hei r pat ent ed seat cl ust er s- - l ot s of l uck.
Those ar e t hei r si gnat ur e and t hey guar d t hose ver y
: cl osel y. Al so, maki ng f acsi mi l i es of anot her bui l der ' s
seat cl ust er coul d easi l y be an i nf r i ngement of a
pat ent .
2- 30
The best bet i s ei t her use one of t he pr evi ousl y
descr i bed t ypes or have your own seat st ay sl ugs or seat
cl ust er manuf act ur ed.
SEAT STAY SLUGS
Ci nel l i has t he best and most avai l abl e sel ect i on
of sl ugs i n ei t her 13mm, 14mmor 16mmsi zes. Some of
t hei r st yl es at e pi ct ur ed bel ow.
ill.74. Cinelli slugs- from1984 Cinelli catalogue
LUG VARI ATI ONS
STAMPED LUGS
Lugs ar e avai l abl e i n t wo maj or t ypes;
1 - St amped l ug set s
2 - I nvest ment cast set s
The st amped l ug set s ar e al so somet i mes cal l ed
sheet met al l ugs. They st ar t out as a f l at pi ece of
sheet met al st ock. The f i r st st ep i s t o put t he pi ece
i nt o a pr ess and st amp out t he r ough shape necessar y
t o make a l ug. Then t he pi ece i s st amped i nt o t he
cont our of t he l ug. Si nce t her e wi l l be a seamaf t er
t hi s st ep, i t must be wel ded bef or e cont i nui ng. Af t er
t he seami s wel ded, anot her st ampi ng pr ocess chops of f
excess mat er i al t o cr eat e t he poi nt s. Thi s i s f ol l owed
by anot her st ep t hat comes i n f r omt he si de and cut s
out t he r ounded bases i n t he l ugs. Fancy cut out s can
al so be st amped out i n one of t hese st eps. The f i nal
st ep f or st amped l ugs i s t o bor e t he i nsi de di amet er ,
2- 31
41.75
.
productionsteps inmakingastampedlug
INVESTMENT CAST LUGS
I nvest ment cast l ugs ar e somet i mes r ef er r ed t o as
bei ng made by t he l ost wax pr ocess. Wi t h i nvest ment
cast l ugs an act ual f ul l si zed copy of t he l ug i s made
out of wax. Thi s wax copy ( I t i s not a mol d) has al l
of t he char act er i st i cs bui l t i nt o i t ( e. g. t ol er ances,
f i ni sh, shape) . The wax copy i s t hen at t ached t o a
"t r ee
"
wi t h ot her wax copi es. Thr ough a t wo week
pr ocess, t he t r ee i s
"
i nvest ed" i n a cer ami c case. By
put t i ng t he whol e assembl y i nt o an oven, t he wax i s
mel t ed away, l eavi ng onl y hol l ow cavi t i es i n t he shape
of t he desi r ed par t s. The por osi t y of t he cer ami c mol d
al l ows ai r t o escape whi l e mol t en st eel i s bei ng pour ed
i nt o i t . Af t er t he cast i ngs ar e cool t he cer ami c mol d
i s br oken away t o l eave t he cast pi eces on t he t r ee.
The i ndi vi dual par t s ar e cut away and t hen heat
t r eat ed.
2- 32
ill.76: produ ction steps In making a cast lu g
COMPARI SONS OF I NVESTMENT CAST AND STAMPED LUGS
Bel ow i s a t abl e maki ng compar i sons of t he t wo
di f f er ent st yl es of l ugs. I t shows advant ages and
di sadvant ages of each.
ADVANTAGES DI SADVANTAGES
CAST
LUGS
Har der mat er i al s such as
Chr ome- mol y or st ai nl ess
can be used. I nsi de
di amet er s can be cast t o
be ver y cl ose t o
necessar y t ol er ances. A
f i ner f i ni sh can be cast
on t he sur f ace of t he
l ug. Less pr epar at i on
f or si l ver br azi ng i s
necessar y. Lugs can be
cast t o mor e exact l y
mat ch f r ame angl es.
Because of cl ose
t ol er ances l ess si l ver
sol der i s needed f or a
j oi nt .
Cast l ugs ar e
usual l y qui t e st ubby
as l ong poi nt s ar e
di f f i cul t t o cast .
Cut out s ar e al so
di f f i cul t t o cast
i nt o a l ug.
Bendi ng cast l ugs
i s di f f i cul t and
al most out of t he
quest i on. Of t en
l ug set s have t o
be pur chased wi t h
angl es t o mat ch
t he wor ki ng dr awi ng.
Cast l ugs ar e qui t e
qui t e expensi ve.
Longer poi nt s can be
desi gned i nt o t he l ug.
STAMPED Fancy cut out s can be
LUGS

desi gned i nt o t he l ug.

The l ug i s sof t er and
2- 33
Pr epar at i on and
cl ean up ar e t i me
consumi ng. Sheet
met al l ugs can dr aw
much mor e si l ver
ADVANTAGES DI SADVANTAGES
modi f i cat i ons can be t han cast l ugs.
made mor e easi l y. The Ext ensi ve r eami ng i s
l ug can be bent up t o a of t en r equi r ed f or a
coupl e of degr ees i f good f i t wi t h t he
necessar y. St amped l ugs t ube. Wel ded seams
ar e much cheaper . ar e of t en unsi ght l y
and may need speci al
at t ent i on. Tabs on
t he seat l ug shoul d
be r ei nf or ced
i nt er nal l y.
Ther e ar e a l ar ge number of l ug set s avai l abl e on
t he mar ket t oday. Her e i s a di scussi on of t he ones
t hat ar e mor e r eadi l y avai l abl e or mor e not abl e f or
some par t i cul ar r eason:
HENRY J AMES
These ar e i nvest ment cast out of chr ome- mol y by
Henr y J ames i n Cal i f or ni a. They ar e ext r emel y har d and
need a mi ni mumof pr ep wor k t o get t hemr eady f or
si l ver br azi ng. They cannot be al t er ed ver y much and
t her ef or e, come i n 1 degr ee i ncr ement s and each l ug can
be or der ed separ at el y t o make up a set . They have
shor t poi nt s and no cut out s. Expect t o pay about
$25. 00 per set of 3.
CI NELLI
These ar e i nvest ment cast but t end t o be qui t e a
bi t sof t er t han ot her s t hus al l owi ng f or some bendi ng
t o meet i ndi vi dual needs. They ar e qui t e l i ght and
r at her pet i t e. They have no cut out s and shor t poi nt s.
They r equi r e a bar e mi ni mumof pr ep wor k. Ol der
Ci nel l i l ugs wer e st amped l ugs and not ver y at t r act i ve.
Be car ef ul when or der i ng not t o end up wi t h one of t he
ol d st amped set s. Expect t o pay about $25. 00 per set .
PRUGNAT
These ar e st amped l ugs and ar e qui t e si mpl e i n
desi gn. They can be bent t o i ndi vi dual needs. They
ar e avai l abl e i n about 4 di f f er ent st yl es r angi ng f r om
pl ai n t o havi ng di f f er ent st yl es of cut out s. They
usual l y r equi r e a l ot of r eami ng t o pr epar e t hemf or
use. Cl eanup wi l l be r at her t i me consumi ng al so.
Expect t o pay about $7. 00 t o $9. 00 per set .
2- 34
TANGE
These ar e st amped l ugs and ar e al so qui t e si mpl e i n
desi gn. They can be bent t o i ndi vi dual needs. They
ar e avai l abl e i n pl ai n or wi t h di amond shaped cut out s.
They r equi r e l i t t l e r eami ng t o pr epar e t hemf or use but
ext er nal cl ean up can be t i me consumi ng. Expect t o pay
$7. 00 t o $9. 00 per set .
HADEN
These ar e st amped l ugs and ar e al so qui t e si mpl e i n
desi gn. They can be bent t o i ndi vi dual needs. They
ar e avai l abl e i n f our st yl es - t wo of whi ch have a
separ at e al i en st yl e bi nder f or t he seat l ug. ' They
have cut out s i n t hr ee st yl es. They r equi r e l i t t l e
r eami ng and l i t t l e ext er i or cl ean up. Expect t o pay
$7. 00 t o $9. 00 per set .
Of cour se t her e ar e l i t er al l y dozens of br ands and
st yl es of l ugs on t he mar ket . The ones ment i oned above
ar e ones I have used ext ensi vel y or have per sonal l y
sought out i nf or mat i on about . For f ur t her quest i ons
about ot her br ands and st yl es cont act ei t her t he
f act or y or a di st r i but or of f r amebui l di ng suppl i es.
BOTTOM BRACKET VARI ATI ONS
As wi t h l ug set s t her e ar e t wo maj or t ypes of
bot t ombr acket shel l s:
I - St amped
2 - Cast
To go over pr oduct i on of t he t wo di f f er ent t ypes
woul d be r edundant as t he pr ocesses ar e near l y
i dent i cal t o t hose used i n t he manuf act ur e of l ug set s.
Al so t he compar i son char t showi ng t he advant ages and
di sadvant ages of st ampi ngs and cast i ngs r eadi l y appl i es
t o bot t ombr acket s. That l eaves a si mpl e di scussi on of
t he di f f er ent bot t ombr acket shel l s avai l abl e on t he
mar ket .
CI NELLI
These ar e i nvest ment cast wi t h f i nel y machi ned
t hr eads and f aces. They r equi r e l i t t l e pr epar at i on f or
si l ver br azi ng asi de f r ommoder at e r eami ng. They ar e
ext r emel y st i f f and ar e di f f i cul t t o col d set . I t i s
not necessar y t o r emove much met al dur i ng t he f i nal
f aci ng pr ocedur e. They ar e r eadi l y avai l abl e i n bot h
Engl i sh and I t al i an specs. Expect t o pay $15. 00 t o
$20. 00
2- 35
HENRY J AMES
These ar e i nvest ment cast out of chr ome- mol y. They
r equi r e l i t t l e pr epar at i on f or si l ver br azi ng asi de
f r ommoder at e r eami ng. They ar e ext r emel y st i f f and
di f f i cul t t o col d set . The manuf act ur er pr ovi des an
ext r a mi l l i met er of wi dt h so t hat i f i t i s necessar y t o
r emove a l ot dur i ng t he f aci ng pr ocedur e t her e i s
l i t t l e r i sk of goi ng under si ze. They ar e avai l abl e i n
Engl i sh specs. Expect t o pay $15. 00 t o $20. 00
RGF
Thi s i s one of t he best st amped bot t ombr acket
shel l s avai l abl e. I t i s even sandbl ast ed t o gi ve a
genui ne cast l ook. I t r equi r es a l ot of r eami ng.
( Good shel l t o use f or Fr ench t ubi ng) Some cl ean up i s
necessar y t o r emove bl emi shes and r i ppl es on t he
ext er i or of t he shel l . Be car ef ul when f aci ng. They
come at exact l y 68mmwi de and i t i s easy t o go
under si ze. They ar e r eadi l y avai l abl e i n Engl i sh
specs. Expect t o pay $7. 00 t o $10. 00
HADEN
Thi s i s a good pr act i ce bot t ombr acket f or usi ng on
your f i r st f i ve bi kes. I t ' s a st ampi ng. The wel ded
seami s pr et t y r ough and needs a l ot of cosmet i c wor k.
Some number s ar e st amped i n t he bot t omsur f ace and ar e
somewhat unsi ght l y. Some of t hese shel l s wi l l act ual l y
come under si zed and wi l l be dr ast i cal l y under si zed
af t er f aci ng. I t al l sounds pr et t y bad but t he pr i ce
i s r i ght . A Haden l ug and bot t ombr acket set i s so
r easonabl e- - i t ' s al most l i ke get t i ng a f r ee bot t om
br acket shel l t o pl ay wi t h.
Al l of t he af or ement i oned bot t ombr acket shel l s
come i n Engl i sh specs. Some come i n I t al i an specs. I f
an I t al i an t hr eaded bot t ombr acket i s needed, r eamand
r et ap an Engl i sh one. The necessi t y of usi ng an
I t al i an bot t ombr acket i s quest i onabl e f or t wo r easons:
1 - I f an Engl i sh or Fr ench shel l st r i ps out or i s
cr oss t hr eaded, i t can al ways be r eamed and
r et apped t o I t al i an. Wi t h an I t al i an bot t om
br acket t hat i s not possi bl e.
2 - The use of a l ef t hand t hr ead on t he r i ght si de
of t he bi ke i s def i ni t el y a super i or concept .
Thi s i s used on Engl i sh and Swi ss* bot t om
br acket s t o pr event l ooseni ng of t he f i xed cup.
*Swi ss has t he same t hr ead as Fr ench but has a l ef t
hand t hr ead on t he r i ght si de.
2- 36
Use of t he Fr ench bot t ombr acket i s al so
quest i onabl e f or t wo r easons:
1 - The Fr ench, l i ke t he I t al i ans, do not use a
l ef t hand t hr ead on t he r i ght si de.
2 - Such a smal l per cent age of t he Amer i can mar ket
i s Fr ench t hat t her e wi l l al ways be at l east a
l i t t l e hassl e i n obt ai ni ng par t s t o f i t Fr ench
specs.
Gener al l y bot t ombr acket shel l s ar e avai l abl e i n
t wo wi dt hs; 68 and 70 mi l l i met er . The 68mmi s
pr ef er abl e si nce t her e ar e mor e bi kes on t he r oad wi t h
t hat wi dt h bot t ombr acket shel l . Hence, par t s ar e mor e
easi l y obt ai nabl e. However , a 70mmshel l al ways has
t he opt i on of f aci ng of f 2mmi f a pr obl emar i ses.
Besi des, good l uck f i ndi ng a good r el i abl e sour ce f or
70mmbot t ombr acket shel l s.
Ther e i s ver y l i t t l e need t o gi ve much ar gument
f or Swi ss bot t ombr acket shel l s. Admi t t edl y, t hey do
use a l ef t hand t hr ead on t he r i ght si de. But , t hey
compr i se such a smal l por t i on of t he mar ket , bot t om
br acket cups wi l l be di f f i cul t t o obt ai n.
Some br ands of t he bot t ombr acket shel l s come wi t h
t he opt i on of choosi ng di f f er ent geomet r i cal specs ( see
pi ct ur e) . The var i at i on of t he angl es ar ound t he
bot t ombr acket i s so l i t t l e t hat a l i t t l e r eami ng of
t he or i f i ces i s usual l y enough t o do t he t r i ck. That
whi ch can
'
t be accompl i shed by r eami ng can be t aken
t ar e of by sl i ght col d set t i ng.
ill.77: bottombracket angles
2-37
FORK CROWN VARI ATI ONS
For k cr owns can be di vi ded i nt o t wo gr oups t hr ee
t i mes over :
1 - St amped or Cast
2 - Br i t i sh or Cont i nent al oval cr oss sect i ons
3 - I nser t ed or Over l appi ng conf i gur at i on ( Fur t her
di vi si ons of Tr ack, Tandemand Mount ai n cr owns
coul d be added t oo but t o l essen t he conf usi on
wi l l not be di scussed) .
On one hand, t he ear l i er di agr ams and t abl e
compar i ng and cont r ast i ng cast and st amped l ugs appl y
t o f or k cr owns. On t he ot her hand, st amped f or k cr owns
ar e al most ar chai c. They ar e st at e of t he ar t of t en
year s ago. Cast cr owns ar e so super i or t o st amped
cr owns t hat st amped cr owns can onl y be r ecommended t o
make a qui ck and cheap r epl acement f or k.
For k bl ade cr oss sect i ons ar e an ongoi ng
cont r over sy. Today t he f at t er , beef i er cont i nent al
bl ade i s enj oyi ng a l ot of popul ar i t y. Ten year s ago
t he t hi nner Br i t i sh bl ade was ver y popul ar . Bot h
bl ades have a def i ni t e pl ace i n t he bi cycl e i ndust r y.
The Br i t i sh bl ade makes a good t our i ng f or k. Al t hough
i t has l ess l at er al st abi l i t y due t o i t s t hi n cr oss
sect i on, i t has mor e st r engt h f r omf r ont t o back. Thi s
means t hat cor ner i ng abi l i t y may be at a bi t of a l oss
but f or war d st abi l i t y when br aki ng wi t h a heavy l oad i s
i mpr oved. The Cont i nent al bl ade makes a bet t er r aci ng
f or k. Because of i t s wi der cr oss sect i on i t has mor e
l at er al st abi l i t y f or bet t er cor ner i ng. Si nce t he
r acer doesn' t car r y a heavy l oad, f or war d st abi l i t y i s
not t hat i mpor t ant .
The t hi r d di vi si on i s i n t he way i n whi ch t he cr own
and t he bl ade ar e at t ached. Wi t h t he i nser t ed cr own,
t he cr own f i t s i nsi de t he bl ade. Wi t h t he
over l appi ng, t he bl ade f i t s i nsi de t he cr own. Bot h ar e
of about t he same st r engt h. One woul d t end t o t hi nk
t hat t he i nser t ed cr own woul d not be as st r ong.
However , t he one f act or t hat woul d be of concer n i n
t hi s case i s account ed f or . Si nce t he por t i on t hat i s
2- 38
i nser t ed i s of a smal l er di amet er , i t i s gi ven a
t hi cker wal l . Thi s makes t he i nser t ed cr own as st r ong
as t he over l appi ng cr own.
Wi t h t hr ee set s of t wo var i abl es i n f or k cr owns,
t he number of br ands of cr owns can be cubed. Thi s wi l l
gi ve a r ough est i mat i on of t he gr eat number of f or k
cr owns on t he mar ket t oday. Ther e ar e l i t er al l y dozens
and dozens of f or k cr owns t o choose f r om. For t hat
r eason, onl y a f ew f avor i t es wi l l be di scussed.
Some ot her mi nor var i at i ons t hat can be f ound i n
f or k cr owns ar e:
1 - Sl ope: r ef er s t o t he angl e at whi ch t he cr own
goes down t o meet t he bl ades. Ful l - sl opi ng,
semi - sl opi ng, and non- sl opi ng ar e t he di f f er ent
t ypes.
2 - St i f f ener s or t angs: ar e decor at i ve pi eces of
sheet met al st ock t hat ar e si l ver br azed t o t he
i nsi de f ace of t he f or k bl ade i mmedi at el y bel ow
t he cr own. They add a ver y not i ceabl e amount
of l at er al st r engt h t o t he f or k.
3 - Count er bor i ng f or al l en nut s: count er bor i ng of
t he br ake hol e can be done i n or der t o use an
al i en t ype br ake nut . Thi s can be done t o any
cr own by t he bui l der .
2- 39
CI NELLI
Ci nel l i has a wi de r ange of cr owns t o choose f r om.
They make al l t ypes except st amped and over l appi ng f or
t he Br i t i sh bl ades. They make cr owns wi t h al l sl ope
pat t er ns. Thei r cr owns r equi r e moder at e r eami ng f or a
good f i t on t he st eer i ng col umn and a mi ni mumcl ean up
( One except i on i s t he f ul l sl opi ng i nser t ed Br i t i sh
cr own whi ch r equi r es massi ve pr ep wor k) . They have a
l ar ge di amet er at t he si t e of t he cr own r ace so t hat
t hei r cr owns can be mi l l ed f or 26. 4mmor 27. 2mm.
Sever al of t he cr owns i n t he Ci nel l i l i ne have t he
opt i on of usi ng st i f f ener s. Expect t o pay $12. 00 t o
$16. 00.
HENRY J AMES
These ar e some of t he ni cest cr owns on t he mar ket .
They have hi dden ai r expansi on hol es and bui l t i n f or k
t angs. Somet i mes t he seams ar e r at her r ough i n t he
cast i ng and r equi r e a l i t t l e ext r a cl ean up. They ar e
out of chr omecool y and ar e di f f i cul t t o col d set af t er
t he f or k i s bui l t . They al so have a speci al di mpl e
cast i nt o t he cr own whi ch aut omat i cal l y l ocat es t he
dr i l l bi t when dr i l l i ng t he br ake hol e. These ar e
about t he t hi ckest cr owns on t he mar ket so i f usi ng one
make sur e t he t hi ckness i s account ed f or i n t he wor ki ng
dr awi ng. Expect t o pay $19. 00 t o $23. 00.
2- 40
ZEUS
Zeus makes t hr ee cr owns:
1 - I nser t ed, cast , Br i t i sh, non- sl opi ng
2 - I nser t ed, cast , Cont i nent al , non- sl opi ng
3 - Over l appi ng, cast , t r ack, non- sl opi ng
They ar e easy t o cl ean up and pr epar e f or si l ver
br azi ng. They ar e one of t he t hi nnest cr owns and i f
usi ng one t hi s shoul d be desi gned i nt o t he wor ki ng
dr awi ng. Expect t o pay $9. 00 t o $12. 00.
DROPOUT VARI ATI ONS
Basi cal l y t her e ar e t hr ee maj or st yl es of dr opout s:
1 - St andar d r oad dr opout s
2 - Ver t i cal dr opout s
3 - Tr ack or r ear l oadi ng dr opout s.
Any ot her t ypes of dr opout s ar e an of f shoot f r om
t hese t hr ee. Ther e ar e some br ands of dr opout s t hat
ar e si mpl y st amped out of 3/ 32" mi l d st eel sheet st ock.
These ar e of i nf er i or qual i t y and wi l l be di scussed no
f ur t her . Most hi gh qual i t y dr opout s ar e f or ged out of
a f ai r l y hi gh qual i t y st eel . The bet t er ones ar e t hen
gi ven r ai sed f aces wher e t he qui ck r el ease comes i n
cont act wi t h t he dr opout .
STANDARD ROAD DROPOUTS
These have l ong ( near l y hor i zont al ) sl ot s f or t he
axl e t o sl i de i nt o. Thi s al l ows t he wheel t o be
j ockeyed back and f or t h bet ween t he chai nst ays t o get
t he t i r e cent er ed pr oper l y. Some of t he mor e expensi ve
r oad dr opout s have smal l adj ust ment scr ews cal l ed chai n
adj ust er s scr ewed i n f r omt he back. Ther e i s a gr oss
mi sconcept i on about t he pur pose of chai n adj ust er s.
Many bi ker s t hi nk t hat t hey ar e f or adj ust i ng t he wheel
base on t he bi ke. Chai n adj ust er s wer e not desi gned
f or t hat pur pose. They wer e desi gned f or t he company
or per son bui l di ng f r ames who coul d not hol d t i ght
t ol er ances on chai nst ay l engt h. By usi ng dr opout s wi t h
chai n adj ust er s t he bui l der r eal l y di dn' t have t o wor r y
so much about t he chai nst ay l engt h on bot h si des
mat chi ng. A di f f er ence of 6mmcoul d be t aken up wi t h
t he chai n adj ust er s. St andar d r oad dr opout s wi t h chai n
adj ust er s have one maj or dr awback - - t he t hr eaded hol e
wher e t he chai n adj ust er goes t hr ough i s i nher ent l y
weak. I f t he bi ke cr ashes or t he r ear der ai l l eur goes
i nt o t he spokes, t he r i ght dr opout coul d shear of f
t hr ough t he t hr eaded hol e.
2- 41
w ith raised faces w ith raised faces,
and hanger
hanger,adju sters & eyelets
Wain
Su ntou r
ill.83: v ertical dropou ts
Shimano G.P Wilson
ill.82: w ide range of dropou t qu ality
VERTI CAL DROPOUTS
Due t o t he f act t hat many f r amebui l der s can hol d
bet t er t ol er ances t oday t he ver t i cal dr opout i s wi del y
used now. Rear t r i angl es must be bui l t wi t h exact i ng
accur acy when usi ng ver t i cal s. Si nce t he axl e si mpl y
bot t oms out i n t he dr opout wi t h ver t i cal s, t hey must be
posi t i oned so t hat a pr oper l y di shed wheel si t s i n t he
mi ddl e of bot h chai nst ays as wel l as seat st ays. Thi s
can be qui t e t r yi ng f or t he begi nni ng f r ame bui l der .
Ver t i cal dr opout s have f our advant ages:
1 - Pul l i ng a t i r e i nt o a chai nst ay due t o a l oose
qui ck r el ease never occur s.
2 - They ar e mor e compact and l i ght er as a r ul e.
3 - Si nce t her e i s no t hr eaded hol e f or a chai n
adj ust er , t hey ar e much st ur di er and have
l i t t l e or no t endency t o shear of f .
4 - Ext r emel y t i ght cl ear ances can be used bet ween
t he r ear t i r e and t he seat t ube.
2-42
TRACK OR REAR LOADI NG DROPOUTS
The r ear l oadi ng dr opout s ar e used f or t wo maj or
r easons:
1 - Due t o t he way t hey ar e at t ached t o t he st ays
t hey ar e st r onger and can st and up t o f r equent
and power f ul spr i nt s bet t er .
2 - Si nce t he wheel l oads f r omt he r ear , t her e can
be ver y t i ght cl ear ances bet ween t he r ear t i r e
and t he seat t ube.
As a gener al r ul e, r ear l oadi ng dr opout s ar e onl y
used on t r ack bi kes.
ill.84: trackdropou ts
FRONT DROPOUTS
Ther e i s not much t o be sai d about f r ont dr opout s.
They si mpl y come wi t h r ear dr opout s i n t he set .
Fr amebui l der s sel dombuy set s of dr opout s based on what
t he f r ont ones l ook l i ke. Fr ont dr opout s ei t her come
wi t h no f ender eyel et s, one eyel et or t wo eyel et s. I f
eyel et s ar e not pr esent and desi r ed, t hey can be si l ver
br azed on. I f t her e ar e eyel et s and t hey ar e not
desi r ed, t hey can be cut of f .
ill.85: factory positioning of front eyelets
Fol l owi ng i s a br i ef di scussi on of some of t he mor e
popul ar dr opout s on t he mar ket . Ther e ar e qui t e a f ew
avai l abl e and t hi s wi l l be a f ai r l y compl et e l i st .
2- 43
THE PATEREK MANUAL FOR BICYCLE FRAMEBUILDERS
THE PATEREK MANUAL FOR BICYCLE FRAMEBUILDERS
ATTACHING DROPOUTS
Dr opout s can be at t ached i n sever al ways. Of
pr i mar y concer n i n at t achi ng t hemi s t he chai nst ay/
dr opout j oi nt . Thi s j oi nt i s under t ensi on dur i ng
r i di ng and r uns a hi gher r i sk of f ai l ur e t han t he
seat st ay/ dr opout j oi nt whi ch i s under compr essi ve
f or ces. The f ol l owi ng ar e opt i ons f or at t achi ng
dr opout s.
SIMPLE BRAZE
I n t he case of domed st ays, br azi ng i s mor e t han
adequat e. The cont i nuous l i ne al ong t he dome gi ves
mor e sur f ace ar ea f or br azi ng al l oy t o bond wi t h.
Si l ver or Br ass ar e ok. However , br ass wi l l exceed t he
cr i t i cal t emper at ur e of st eel .
BRAZE FILLED
Wi t h t he mi l l ed ( see pg. 2- 56) st yl e st ayends, a
r at her l ar ge gap has t o be f i l l ed. Low t emper at ur e
br ass, ni ckel si l ver , or ni ckel br onze ar e good f or
j oi ni ng and f i l l i ng at t he same t i me.
SPLIT CYLINDER INSERTS
As i s t he case i n any ot her j oi nt on t he f r ame,
i ncr eased sur f ace ar ea i s desi r abl e. Thi s gi ves t he
si l ver mor e ar ea t o occupy. Hence, mor e hol di ng power .
G. P. Wi l son of San Di ego, Cal i f or ni a advi ses i nser t i on
of spl i t cyl i nder s bef or e si l ver br azi ng.
PINNING
Drilling a t r ansver se hol e t hr ough t he st ay end and
dr opout t ab can be done bef or e br azi ng. A st eel pi n i s
i nser t ed pr i or t o br azi ng. Af t er br azi ng, t he pi n i s
f i l ed f l ush. Thi s met hod can be done i n addi t i on t o
any of t he t hr ee pr evi ous met hods.
Dropou t joints - b raz ing alloy rou ghly occu pies crosshatched area
2-46
TUBI NG VARI ATI ONS
Ther e ar e sever al maj or manuf act ur er s of bi cycl e
f r ame t ubi ng i n t he wor l d t oday. Some of t he mor e
popul ar ones ar e; Reynol ds, Col umbus, I shi wat a,
Tange- Champi on, Vi t us, Dur af or t , Tr ue Temper and Or i a.
Ther e ar e al so br ands of t ubi ng t hat ar e made
excl usi vel y f or a par t i cul ar bi cycl e company and ar e
not avai l abl e t o i ndependent f r amebui l der s. A good
exampl e of t hi s woul d be Fuj i ' s Val i t e t ubi ng. The
onl y t ubi ng t hat wi l l be di scussed i n t hi s sect i on wi l l
be t he br ands t hat ar e avai l abl e t o bui l der s.
Tubi ng i s avai l abl e i n ei t her Fr ench speci f i cat i ons
or Br i t i sh speci f i cat i ons. The mai n di f f er ences
bet ween t hese t wo ar e t he wal l t hi cknesses and t he
out si de di amet er s of t he t ubes. The Br i t i sh t ubes ar e
manuf act ur ed t o t he near est even i ncr ement i n t he
Engl i sh measur i ng syst em, i . e. 1", 1/ 8", 1 1/ 4", et c.
Fr ench t ubes ar e made t o t he near est met r i c i ncr ement ,
i . e. 26mm, 28mm, 32mmet c. Thi s makes Fr ench t op t ubes
sl i ght l y l ar ger i n di amet er t han Br i t i sh t op t ubes
( Thi s i s why i t i s ver y di f f i cul t t o put t op t ube br ake
cabl e cl i ps on a Fr ench bi ke) . The Br i t i sh seat and
down t ubes ar e sl i ght l y l ar ger i n di amet er t han Fr ench
( Thi s i s why a st andar d f r ont der ai l l eur wi l l t end t o
t wi st on a Fr ench f r ame) . Di f f er ences bet ween Fr ench
and Br i t i sh t ubi ng di ct at e t he use of speci al l y made
l ugs and bot t ombr acket shel l s t o mat ch t he nat i onal i t y
of t he t ube set s. For t hi s r eason, onl y Br i t i sh t ube
set s wi l l be di scussed i n t hi s sect i on.
2- 47
Tubi ng set s come wi t h a var i et y of wal l t hi cknesses
and t aper s. Some ar e pl ai n gauge t ubi ng and ot her s ar e
"
but t ed
"
t ubes whi ch change i n wal l t hi ckness f r omone
end of t he t ube t o t he ot her . Si nce hi gh qual i t y
f r ames shoul d usual l y be bui l t wi t h but t ed t ubes and
t aper gauge bl ades and st ays, t hose wi l l be t he t ube
set s t hat wi l l be di scussed t he most i n t hi s sect i on.
THE DOWN TUBE
The down t ube whi ch connect s t he bot t omhead l ug
and t he bot t ombr acket i s one of t he onl y t wo t ubes
t hat i s doubl e but t ed. The wal l t hi ckness at t he ends
of t he t ube i s a heavy gauge and t he wal l t hi ckness at
t he cent er of t he t ube i s a l i ght gauge. Yet t he
over al l out er di amet er f r omone end of t he t ube t o t he
ot her r emai ns uni f or mat 1 1/ 8". Thi s means t hat al l
of t he al t er at i ons t o t he t ube have been done t o t he
i nsi de sur f ace. Thi s way, i t i s undet ect abl e t hat
anyt hi ng speci al has been done t o t he t ube ( For a mor e
compl et e descr i pt i on of how but t ed t ubes ar e f or med, a
bookl et cal l ed "TOP TUBES" can be or der ed f r omTI
Reynol ds) .
Of speci al concer n t o t he f r amebui l der ar e mi t er i ng
and cut t i ng of t he down t ube. Cut t i ng t oo much of t he
but t ed end of f coul d el i mi nat e t he but t al t oget her .
Thi s woul d mean t hat wher e t he t ube i s j oi ned wi t h a
l ug, onl y a t hi nwal l t ube i s pr esent . Such a condi t i on
woul d mean a subst ant i al l y weakened f r ame f r omt he
st ar t . For t hi s r eason, t he maj or t ube manuf act ur er s
have made speci al pr ovi si ons so t hat t he whol e but t ed
ar ea i s not cut of f . Reynol ds pr ovi des a l ong but t at
one end. By cut t i ng t he excess of f t he l ong but t , a
bui l der can avoi d cut t i ng of f t he ent i r e but t ed ar ea.
The shor t but t i s t he end on whi ch t he Reynol ds name i s
st amped. The shor t but t ed end shoul d be mi t er ed f i r st
but do not cut any mor e of f . Opposi t e t he end wher e
t he name i s st amped i s t he l ong but t . Dur i ng t he f i nal
f i t t i ng of t he t ube, any excess can be cut f r omt hi s
end. Col umbus of f er s t hr ee si ze r anges i n near l y al l
of t hei r t ube set s. For a smal l er r i der , an A set
shoul d be or der ed. For a mi ddl e si zed r i der , a B set
shoul d be or der ed. For a t al l r i der a C set shoul d be
or der ed. Excess may be cut of f ei t her end of t he down
t ube i n any Col umbus set si nce t he l engt h desi r ed wi l l
so cl osel y mat ch t he A, B, or C set or der ed. A f ew
set s come wi t h si ngl e but t ed down t ubes. Put t he but t
at t he head t ube.
2- 48
THE TOP TUBE
The t op t ube whi ch connect s t he t op head l ug and
t he seat l ug i s t he onl y ot her doubl e but t ed f r ame t ube
i n t he t ube set . Ot her t han t he f act t hat i t has an
out er di amet er of 1
"
, al l ot her per t i nent i nf or mat i on
i s t he same as t hat f or t he down t ube. See t he
pr evi ous subheadi ng f or any cut t i ng or mi t er i ng
r ecommendat i ons. A f ew set s come wi t h si ngl e but t ed
t op t ubes. Put t he but t at t he head t ube.
THE SEAT TUBE
The seat t ube i s onl y si ngl e but t ed. Thi s i s t o
al l ow f or t he i nser t i on of t he seat post i n t he
t hi nwal l end of t he t ube. I F t he seat t ube wer e doubl e
but t ed, i t woul d be di f f i cul t t o t el l what di amet er
seat post woul d be necessar y. Fur t her mor e, i f t he
seat post wer e t o be i nser t ed i nt o a doubl e but t ed t ube
whi ch was cut at a l ocat i on j ust bef or e t he but t , t he
seat post woul d r ock and st ar t t o r eamt he t op of t he
seat t ube. Wi t h a si ngl e but t ed seat t ube, sever al
i nches can be cut of f and t he same si ze seat post wi l l
st i l l f i t . The out er di amet er of t he seat t ube i s 1
1/ 8".
I n cut t i ng and mi t er i ng t he seat t ube i t i s ver y
i mpor t ant t o mi t er t he but t ed end t o come i n cont act
wi t h t he bot t ombr acket shel l . Ther e ar e t hr ee ways t o
t el l whi ch i s t he but t ed end:
1 - Reynol ds st amps t hei r name i n t he but t ed end
whi l e Col umbus st amps t hei r l ogo i n t he but t ed
end.
2- 49
2 - Si nce a vast maj or i t y of t ube set s accept a
27. 2mmdi amet er seat post , keep one on hand t o
see whi ch end of t he seat t ube i t can be pushed
i nt o.
3 - Compar e t he wal l t hi ckness of each end of t he
t ube ei t her by eye or wi t h a t ubi ng mi cr omet er
t o see whi ch end i s t he but t ed end. When t he
but t ed end i s det er mi ned, wr ap a band of
maski ng t ape ar ound t he opposi t e end. Thi s
wi l l el i mi nat e any conf usi on as t o whi ch end i s
whi ch l at er and al so di st i ngui sh t he seat t ube
f r omt he down t ube as wel l . Any excess i n
l engt h shoul d be r emoved f r omt he t hi nwal l end
of t he seat t ube.
The l engt h of t he seat t ube, as i t comes i n t he
t ube set , i s cr i t i cal i n det er mi ni ng how bi g of a f r ame
can be bui l t out of t hat par t i cul ar t ube set . Take t he
over al l l engt h of t he seat t ube as i t comes i n t he ki t .
Add 25 mi l l i met er s t o t hat l engt h. The r esul t i ng
f i gur e wi l l gi ve t he l ar gest si ze t hat can be bui l t
f r omt hi s ki t ( Mor e exper i enced bui l der s devel op
subt l e ways t o cheat by near l y a cent i met er . By
sl i ght l y al t er i ng t he mi t er at t he bot t ombr acket and
doi ng a 1cmspl i ce wi t hi n t he seat l ug, a whol e
cent i met er can be gai ned i n seat t ube l engt h) .
Col umbus Tubi ng comes i n A, B, and C set s. The A set
i s f or bi kes wi t h shor t seat t ubes. The B set i s f or
bi kes wi t h medi uml engt h seat t ubes. The C set i s f or
t al l bi kes. I f a f r ame i n excess of 64cmmust be
bui l t , or der t he Reynol ds t al l set . Thi s set comes
wi t h ext r a l ong t ubes f or t he f r ont t r i angl e. However ,
st ays and bl ades must be or der ed separ at el y. A f ew
set s come wi t h doubl e but t ed seat t ubes. Do not use
t hese f or ext r emel y smal l bi kes.
THE HEAD TUBE
The head t ube i s not but t ed at al l . I t has an
out si de di amet er of 1 1/ 4" and usual l y has a wal l
t hi ckness of 1mm. Si nce t he head t ube i s not but t ed i n
any way and nei t her end i s mi t er ed, t her e ar e no r eal l y
i mpor t ant cut t i ng pr ocedur es. Ei t her end can be cut
and any amount can be cut of f . Agai n, f or l onger or
2- 50
shor t er head t ubes, Col umbus of f er s A, B, and C set s.
Reynol ds has ext r a l ong head t ubes t hat ar e ei t her
st ocked by j obber s or can be or der ed f r omReynol ds.
A wor d about wal l t hi cknesses of head t ubes- -
Col umbus head t ubes have a sl i ght l y t hi cker wal l t han
Reynol ds. Thi s has advant ages as wel l as di sadvant ages.
The mai n advant age of a t hi cker wal l i n t he head t ube
i s t hat a st r onger f r ont t r i angl e i s t he di r ect r esul t .
The mai n di sadvant age of t hi cker wal l s on t he head t ube
i s i n t he mi l l i ng and r eami ng pr ocedur e. Hand mi l l i ng
wi t h a Campagnol o #733 t ool or equi val ent i s ver y
di f f i cul t on Col umbus head t ubes.
THE STEERI NG COLUMN
The st eer i ng col umn i s si ngl e- but t ed and t hr eaded
at t he t hi nwal l end. The out er di amet er of t he col umn
i s 1". The but t ed end of t he st eer i ng col umn i s 50mm
l ong and t he t hi nwal l end i s t hr eaded t o 50mm. Cut t i ng
of t he st eer i ng col umn i s ver y cr i t i cal ! I f t oo much
i s cut of f of t he but t ed end, t her e i s no r ei nf or cement
wher e t he st eer i ng col umn goes t hr ough t he f or k cr own.
Cut t i ng of f t oo much of t he t hr eaded por t i on does not
l eave enough t hr eads t o i nst al l a headset . Never cut
mor e t han 3cmof f of t he but t ed end of t he st eer i ng
col umn! Never cut mor e t han 3cmof f of t he t hr eaded
end of t he st eer i ng col umn. Wi t h t hese gui del i nes, a
st eer i ng col umn can be as much as 6cml onger t han
necessar y and st i l l be sui t abl e f or use. I n case of a
t oss- up on how much t o cut of f of each end- - t r y t o cut
l ess of f t he but t ed end.
I f t he st eer i ng col umn i s mor e t han 6cmt oo l ong,
do one of t he f ol l owi ng:
1 - I f usi ng Col umbus t ubi ng, see i f t he cor r ect A,
B or C set has been or der ed. Or der
accor di ngl y.
2. I f usi ng Reynol ds, di f f er ent l engt h st eer i ng
col umns can be or der ed f r omei t her t he j obber
or di r ect l y f r omReynol ds.
3 - I f t he bui l der has st eer i ng col umn di es, t ap
addi t i onal t hr eads ont o t he st eer i ng col umn and
cut excess of f of t he t hr eaded por t i on of t he
col umn.
2- 51
NOTE: I f st eer i ng col umn di es ar e on hand, i t i s
al ways mor e desi r abl e t o add mor e t hr eads t o
t he st eer i ng col umn and l eave t he but t ed end
i nt act i f possi bl e.
Pr obl ems can ar i se i f t he st eer i ng col umn i s bei ng
used i n a ver y smal l f r ame set . The mai n pr obl emt hat
can occur i n t hi s case i s havi ng t oo l ong of a but t .
I f t he but t i s t oo l ong, t he st emwi l l be pr event ed
f r ombei ng i nser t ed f ar enough. For r eal l y shor t
bi kes, t her e must be at l east 50mmof t hi nwal l i n t he
st eer i ng col umn. I n some cases, t hi s may r equi r e t hat
t he but t ed end be cut shor t er t han pr evi ousl y
r ecommended.
Some st eer i ng col umns ar e f anci er t han ot her s.
Col umbus pr ovi des a but t ed st eer i ng col umn whi ch has
i nt er nal spl i nes al ong t he l engt h of t he but t . These
r i dges ar e on t he i nsi de sur f ace and f or ma gr adual
spi r al . They not onl y have t he ef f ect t hat
'
s t he same
as usi ng a t hi cker but t - - t hey al so pr ovi de a t or si onal
st r engt h not pr esent i n r egul ar but t ed st eer i ng
col umns. Fur t her mor e, t hey add some cl ass t o t he
f r ameset . I shi wat a al so of f er s t he same opt i on i n a
f ew sel ect ed t ube set s.
FORK BLADES
For k bl ades ei t her come as pl ai n gauge or t aper
gauge. Taper gauge i s di f f er ent f r ombut t ed t ubes. I n
t he case of but t ed t ubes, t her e i s a sudden and al most
r adi cal change i n t he gauge of t he t ubi ng al ong t he
l engt h of t he t ube. I n t he case of t aper ed t ubes, t he
gauge gr adual l y changes f r omheavy t o l i ght over t he
ent i r e l engt h of t he t ube. By l ooki ng t hr ough t he t ube
at a l i ght sour ce, one can act ual l y see t he begi nni ng
of t he but t ed sect i on of a but t ed t ube. Thi s i s not
possi bl e wi t h a t aper ed t ube. Taper ed f or k bl ades ar e
made by a f our or f i ve st ep pr ocess:
1 - A r ound t ube wi t h a t aper ed gauge i s pr oduced.
Thi s i s t hi ckwal l ed at one end and t hi nwal l ed
at t he ot her .
2- 52
2 - The t aper gauge t ube i s t hen swaged t o f or mt he
ext er nal t aper t hat t ypi f i es f or k bl ades.
Af t er swagi ng t he t aper gauge i s al most
i mper cept i bl e or even gone al t oget her . At t hi s
poi nt t he f or k appear s t o have a uni f or mwal l
t hi ckness f r omt op t o bot t om. Thi s i s because
swagi ng decr eases t he out er di amet er and at t he
same t i me i ncr eases t he wal l t hi ckness.
3 - Opt i onal st ep - - The ends may be domed and
sl ot t ed at t hi s poi nt .
4 - The t op of t he f or k bl ade i s f or med i nt o an
oval cr oss sect i on.
5 - The bend ( r ake) i s put i n t he f or k at t hi s
t i me. Thi s may be done i n mass at t he f act or y
or i ndi vi dual l y by t he i ndependent bui l der .
Pl ai n gauge f or ks ar e made by a sl i ght l y di f f er ent
pr ocess:
1 - A r ound, pl ai n gauged t ube i s pr oduced. Thi s
has uni f or mwal l t hi ckness over t he ent i r e
l engt h of t he t ube.
2 - The pl ai n gauged t ube i s t hen swaged t o f or m
t he ext er nal t aper t hat t ypi f i es f or k bl ades.
Af t er swagi ng t he f or k appear s t o have a
r ever se t aper t han t hat whi ch woul d be
desi r abl e. Thi s i s because t he swagi ng has
decr eased t he out er di amet er at t he f or k t i ps
and at t he same t i me i ncr eased t he wal l
t hi ckness at t he t i ps. Now t he bl ades ar e
t hi nwal l ed at t he t ops and t hi ckwal l ed at t he
t i ps.
3 - Opt i onal st ep - - The ends may be domed and
sl ot t ed at t hi s poi nt .
4 - The t op of t he f or k bl ade i s f or med i nt o an
oval cr oss sect i on.
5 - The bend i s usual l y put i n at t he f act or y on
pl ai n gauge bl ades as most ki t s do not have
pl ai n gauge f or k bl ades.
Cut t i ng of f or k bl ades i s usual l y f ai r l y si mpl e.
Af t er t he bl ade i s bent and t he dr opout s ar e br azed
i nt o pl ace, t he excess i s cut of f of t he t ops.
Ther e ar e some i nst ances i n whi ch some excess may need
t o be cut of f of t he t i ps bef or e t he dr opout s ar e
at t ached. I f t he bl ade i s pr ebent and has mor e r ake
t han i s desi r ed, cut no mor e t han a cent i met er of f of
t he t i ps t o al t er t he r ake somewhat . Some mount ai n
bi ke ki t s and t andemki t s use t he same specs f or f or k
bl ades and chai nst ays. Thi s somet i mes l eaves t he
bui l der wi t h f or k bl ades t hat ar e f ar t oo l ong.
Cut t i ng al l of t he excess of f of t he t ops coul d put t he
cr own t oo cl ose t o t he poi nt wher e t he ext er nal t aper
st ar t s. I n such a case, some excess shoul d be cut of f
of t he t i ps and t he r est shoul d be cut of f of t he t ops.
2- 53
CHAI NSTAYS
Al l of t he i nf or mat i on r egar di ng t aper gauges and
pl ai n gauges i n f or ks i s appl i cabl e t o chai nst ays as
wel l . St eps 1, 2, and 3 i n t he pr oduct i on of
chai nst ays ar e t he same as i n t he pr oduct i on of f or k
bl ades. For st ep 4, t he f or war d por t i on of t he
chai nst ays ar e f l at t ened, f l ut ed or oval ed t o al l ow f or
pr oper cl ear ances bet ween t he t i r e and chai nst ays and
spr ocket and chai nst ays. St ep 5 i s, of cour se,
el i mi nat ed. Chai nst ays wi l l come i n one of sever al
conf i gur at i ons:
1 - Round- oval - r ound - - Some chai nst ays ar e r ound
wher e t hey ar e i nser t ed i nt o t he bot t ombr acket
shel l . Movi ng away f r omt he shel l , t hey
gr adual l y become oval i n cr oss sect i on f or
about 5cm. They t hen go back t o a r ound cr oss
sect i on f or t he r est of t he l engt h. The oval ed
ar ea al l ows f or necessar y cl ear ances. The
r ound- oval - r ound conf i gur at i on l eaves l ess
chance of st r ess f r act ur es as t her e ar e no
di mpl es or cr eases i n t he chai nst ay.
2 - Fl at t ened - - Some chai nst ays come wi t h a smal l
f l at ar ea whi ch i s f or t i r e and spr ocket
cl ear ance. The f l at t ened ar eas ar e j ust enough
t o pr ovi de t he pr oper amount of cl ear ance.
These ar eas ar e somewhat abr upt and t end t o be
mor e vi si bl e t han R- O- R.
3 - Fl ut ed - - Some chai nst ays come wi t h ext r emel y
deep i ndent at i ons f or t he t i r e cl ear ance. Deep
f l ut es l i ke t hi s ar e sel domnecessar y and
cr eat e an i nher ent l y weak spot i n t he
chai nst ay. Fl ut ed chai nst ays ar e hi ghl y
suscept i bl e t o st r ess cr acks. Unl ess excessi ve
t i r e cl ear ance i s necessar y, avoi d usi ng f l ut ed
chai nst ays.
4 - Round Some chai nst ays come wi t h no
pr ovi si ons f or cl ear ances at al l . These must
be i ndent ed or oval ed by t he bui l der .
Cut t i ng of chai nst ays i s r at her si mpl e. Ther e i s
sel dom, i f ever , any r eason t o cut anyt hi ng of f of t he
smal l di amet er end of t he chai nst ays. Excess shoul d
2- 54
ROR rou nd flu ted flattened
usual l y be cut of f of t he l ar ge di amet er end af t er t he
dr opout s have been si l ver br azed i n.
ill.92: transv erse cross sections (AB) of chainstays
SEAT STAYS
Seat st ays can al so come as t aper gauge or pl ai n
gauge. Pr oduct i on of seat st ays i s r at her si mpl e. A
t aper gauge or pl ai n gauge t ube i s swaged t o cr eat e t he
desi r ed ext er nal t aper . Then t he smal l di amet er end
may be domed and sl ot t ed. I nf or mat i on on t he
pr oduct i on of f or k bl ades al so appl i es t o seat st ays.
Basi cal l y, t he onl y t hi ng t o wat ch f or i n seat
st ays i s t he out si de di amet er . Some ar e a 14mmseat
st ay whi ch makes a l i ght er r ear t r i angl e. Some ar e a
16mmseat st ay whi ch pr oduces a st r onger r ear t r i angl e.
Reynol ds has r ecent l y i nt r oduced a doubl e t aper .
Cut t i ng seat st ays i s r at her si mpl e. Af t er t he
smal l end i s sl ot t ed t o f i t t he t abs on t he dr opout ,
t he excess shoul d be cut of f t he l ar ger end.
11.93: external tapers of seat stays
BRIDGE MATERIAL
Some t ube set s come wi t h a pi ece of 1/ 2
"
di amet er
t ubi ng about 7cml ong. Thi s i s meant t o be used f or
br ake br i dges. Somet i mes t hi s l i t t l e pi ece i s packed
i nt o one of t he seat st ays. When st ar t i ng t he bui l di ng
of t he f r ame, l ook i nsi de al l of t he bl ades and st ays
2- 55
plain
t o see i f t her e i s a l i t t l e pi ece of br i dge mat er i al
hi dden i nsi de. I f t he f r ame i s assembl ed wi t h t hi s
pi ece i nsi de, t he noi se can dr i ve t he r i der cr azy. I f
pr ef abr i cat ed br i dges ar e t o be used, don' t t hr ow t he
br i dge mat er i al away. Shor t scr aps of t ubi ng l i ke t hat
come i n handy qui t e of t en.
STAY AND BLADE ENDS
The ends or t i ps of seat st ays, chai nst ays, and
f or k bl ades may or may not be al t er ed at t he f act or y.
Reynol ds usual l y pr ovi des a dome and a sl ot on t hei r
t i ps. Col umbus pr ovi des a bevel on t hei r t i ps and t he
bui l der must cut t he sl ot s. Some compani es l eave t hei r
t i ps pl ai n and t he bui l der must use i magi nat i on.
Reynolds Colu mb u s
111.91.: b lade and stay ends
Her e ar e t hr ee popul ar ways of f i ni shi ng t he t i ps
of st ays and bl ades:
ill.95: popu lar w ays of finishing tips
TUBE SUBSTITUTIONS
A bui l der does not have t o use a t ube set as i t
comes i n t he box. Any t ube can be r epl aced wi t h
anot her br and or anot her gauge. A bui l der coul d bui l d
a f r ame wi t h t andemchai nst ays and f or k bl ades, a 1
1/ 8" x . 065" chr ome- - cool y down t ube, Col umbus head t ube
and st eer i ng col umn, and 16mmseat st ays. Such a bi ke
woul d be ver y st ur dy and ext r emel y heavy. On t he ot her
hand a bui l der coul d j ust put a set of Col umbus SP
2- 56
chai nst ays and down t ube i nt o a Col umbus SL t ube set .
Thi s woul d make a ni ce l i ght wei ght f r ame f or someone
who i s j ust a l i t t l e t oo heavy t o r i de an SL f r ame set .
Chr ome- mol y ai r cr af t t ubi ng i s an excel l ent sour ce f or
t ube subst i t ut i ons. Ai r cr af t t ubi ng al l ows a bui l der
t o bui l d a f r ame set t o al most any si ze desi r ed.
One pr obl emar i ses wi t h t ube subst i t ut i ons.
Bi cycl e f r ame t ubi ng manuf act ur er s wi l l not war r ant y
mat er i al s i n a f r ame set t hat mi xes and mat ches
di f f er ent br ands.
TUBI NG COMPARI SON CHARTS
The f ol l owi ng char t s have been compi l ed f r om
br ochur es put out by t he f our mai n cycl e t ubi ng
compani es; Col umbus, I shi wat a, Reynol ds, and Tange. A
gr eat deal of t i me was t aken t o put al l uni t s i n one
measur i ng syst em ( METRI C) , and al so t o put al l
i nf or mat i on i n t he same f or mat . Thi s al l ows t he
bui l der t o scan al l t ube set s on t he mar ket at a gl ance
and make j udgment s on whi ch set t o use. Fol l owi ng i s
a br i ef descr i pt i on of how t o r ead t he char t s:
TUBE LENGTHS - - Al l t ube l engt hs ar e gi ven i n
mi l l i met er s.
TUBE DI AMETERS - - Al l t ube di amet er s ar e gi ven i n
mi l l i met er s. A maj or i t y of t he t ube di amet er s
ar e const ant t hr oughout t he i ndust r y. The mai n
di f f er ences whi ch come up ar e i n t he Fr ench
speci f i cat i ons. Reynol ds i s t he onl y one of t he
t ube compani es whi ch mar ket s Fr ench di amet er
t ubes i n addi t i on t o Br i t i sh. Fr ench specs ar e
l i st ed on t he l ast l i ne of t he Reynol ds char t .
- - I n t he case of chai nst ay di amet er s, t wo
number s ar e gi ven. Si nce t hey ar e t aper ed, a
di amet er i s gi ven f or t he l ar ge end and anot her
di amet er i s gi ven f or t he smal l end.
- - I n t he case of seat st ay di amet er s, t wo or
t hr ee number s ar e gi ven. Si nce t hey ar e
t aper ed, a di amet er i s gi ven f or t he l ar ge end
and anot her number i s gi ven f or t he smal l end.
I n t he case of Reynol ds, some seat st ays ar e
doubl e t aper ed. Thi s means t hat bot h ends ar e
smal l and t he por t i on at t he l ocat i on of t he
br ake br i dge i s a l ar ge di amet er . Hence, t hr ee
number s.
- - I n t he case of f or k bl ades, not onl y ar e t hey
t aper ed, but t hey ar e oval ed at t he t op as
wel l . The f i r st set of number s ( exampl e 28 x
19) i ndi cat e t he out er measur ement s of t he oval
2- 57
t aken at r i ght angl es t o each ot her . The l ast
number i s t he Out er Di amet er ( O. D. ) wher e t he
dr opout goes i n. Tr ack f or k bl ades ar e r ound
at t he t op and wi l l onl y have t wo number s i n
t he squar e.
WALL THI CKNESS - - Al l wal l t hi cknesses ar e gi ven i n
t ent hs of a mi l l i met er . I f one number appear s
i n t he squar e, t hi s i ndi cat es a pl ai n gauge
t ube. Two number s i n a squar e i ndi cat es a
but t ed t ube. Tange of f er s one seat t ube t hat
i s "t r i pl e but t ed"; t hi s appear s wi t h t hr ee
number s i n t he squar e. Tange al so has one
doubl e but t ed seat t ube t hat has a di f f er ent
wal l t hi ckness at each end. Thi s al so appear s
wi t h t hr ee number s i n t he squar e. A smal l
l ower case l et t er may al so appear i n t he squar e
i n whi ch case; s =si ngl e but t ed, d =doubl e
but t ed, t =t r i pl e but t ed, p =pl ai n gauge. I n
t he case of some bl ades and st ays t hat have a
t aper i n t hei r gauge, a capi t al T =t aper
gauge. Reynol ds gi ves t he I nt er nal Di amet er
( I . D. ) on al l of t hei r st eer i ng col umns. I . D.
i s act ual l y onl y a t heor et i cal measur ement i n
t he manuf act ur e of t ubi ng and f or t hi s r eason
t hat col umn on t he r eynol ds char t has been l ef t
bl ank. However , Reynol ds' Br i t i sh col umns t ake
a 22. 2mmst emas do al most al l ot her st eer i ng
col umns i n t hese char t s ( Thei r Fr ench
st eer i ng col umns t ake a 22mmst em) . An X i n
t he st eer i ng col umn squar e i ndi cat es i nt er nal
spl i nes.
TOTAL WEI GHT - - The t ot al wei ght of al l set s i s
gi ven i n gr ams. Si nce Col umbus put s out an A
set f or shor t r i der s, a B set f or medi umhei ght
r i der s, and a C set f or t al l r i der s, i t i s
assumed t hat t he wei ght s gi ven ar e f or A set s.
Wei ght f i gur es on t he A set s woul d appear mor e
al l ur i ng i n t he mar ket pl ace. No wei ght has
been gi ven f or t he Reynol ds Tal l set or t he 453
TECH as t hey ar e i ncompl et e set s t hat r equi r e
addi t i onal t ubes bef or e bei ng compl et e.
NATI ONALI TY - - Thi s appear s on t he Reynol ds char t
onl y. I t si mpl y i ndi cat es i f a t ube i s
avai l abl e i n Fr ench ( F) , Br i t i sh ( B) , or bot h
( F&B) .
RECOMMENDED USES - - I t was di f f i cul t t o desi gnat e
def i ni t e uses f or i ndi vi dual t ube set s as r i der
wei ght , r i der exper i ence, and i nt ended use al l
have t o be j uggl ed t o get a happy medi um. Many
of t he r ecommended uses ar e st r ai ght f r omt he
2- 58
br ochur es wor d- f or - wor d. Ot her s needed t o be
changed a l i t t l e. St i l l ot her s wer e r ewor ded
al t oget her . As t hey ar e i n t he char t s, t he
i nt ended uses wi l l keep t he bui l der out of
t r oubl e. I n ot her wor ds, t he r ecommended uses
ar e al l modest and conser vat i ve. Thi s gi ves
t he bui l der a st ar t i ng poi nt . It i s up t o t he
i ndi vi dual bui l der whet her he want s t o r i sk
put t i ng a heavy r i der on SL t ubi ng or i f he
want s t o bui l d a t our i ng bi ke out of KL. Heavy
r i der s shoul d not be put on t hi n t ubes.
I nexper i enced r i der s shoul d not be put on t hi n
t ubes. Tour i ng, commut i ng, and ci t y bi kes
shoul d not be bui l t out of t hi n t ubes. Af t er
t he r ecommended use t her e wi l l appear 2
abbr evi at i ons. The f i r st t el l s whet her t he set
i s r ecommended f or l i ght , medi um, or al l
r i der s. The second abbr evi at i on t el l s whet her
t he set i s r ecommended f or exper i enced, al l , or
begi nni ng r i der s.
TENSILE STRENGTH CHART
The t ensi l e st r enght char t was al so compi l ed f r om
i nf or mat i on gi ven i n manuf act ur er s
'
br ochur es. Her e
agai n, t i me had t o be t aken t o put al l val ues i n t he
same uni t s. Tensi l e st r engt hs appear as ki l ogr ams per
squar e mi l l i met er . However , t hr ee of t he f our
manuf act ur er s gave f i gur es i n kg/ mm
2
and one gave
f i gur es i n PSI . Hence, i t was easi er t o conver t t he
r emai ni ng one t o kg/ mm
2
. Fur t her mor e, conver t i ng mass
f i gur es t o f or ce f i gur es i s onl y t heor et i cal .
Ther ef or e, conver t i ng t hese val ues t o Newt ons/ mm
2
l acks
some cr edi bi l i t y. To el i mi nat e t hese di scr epanci es al l
t ubes shoul d have been t est ed by one unbi ased t est i ng
agency and al l val ues shoul d have been expr essed i n
Newt ons/ mm2.
COMPOSITION CHART
Onl y t wo compani es gave the composi t i on of t hei r
al l oys. Ther ef or e, a compl et e compar i son cannot be
made bet ween al l f our compani es. However , t he
i nf or mat i on i s i nt er est i ng to t ake not e of .
MISCELLANEOUS DISCREPANCIES
Occasi onal l y t her e was a mi spr i nt i n t he
manuf act ur er s' br ochur es. I n t hese cases a l i t t l e bi t
of i nt er pol at i on was ut i l i zed t o r ecor d a r easonabl e
val ue i n t he char t s.
FORK BLADE RAKE -- For k bl ade r ake was not
i ncl uded i n t hese char t s as not enough
i nf or mat i on was avai l abl e t o make i t meani ngf ul .
2- 59
As a gener al r ul e; Al l Col umbus bl ades come
st r ai ght and must be bent by t he bui l der .
Reynol ds bl ades can be or der ed bent or st r ai ght .
On most Reynol ds set s t hey ar e r aked 45mmf or
r aci ng set s or 50mmf or t our i ng set s.
CHAI NSTAY CROSS- SECTI ON - - Her e agai n i t was
di f f i cul t t o put somet hi ng meani ngf ul t oget her .
As a gener al r ul e; You get what t he specs cal l
f or wi t h Reynol ds and t her e
'
s no t el l i ng what
wi l l pop out of t he box wi t h Col umbus.
BLADE AND STAY TI PS - - Thi s i s j ust a t oo
mi ni scul e i t emt o i ncl ude i n t he char t s.
COLUMBUS STEERI NG COLUMN/ HEAD TUBE LENGTHS - - As
near as can be det er mi ned, t he A, B, and C set s
each have a si ze r ange t hat can be expect ed f or
st eer i ng col umn and head t ube l engt hs.
Ther ef or e, an exact val ue cannot be put i n t hose
squar es.
COLUMBUS TENSI LE STRENGTH - - The f i gur es on
t ensi l e st r engt h appear i ng i n t he 1984 Col umbus
br ochur e wer e ver y di f f i cul t t o i nt er pr et . The
f i gur e t hat appear s i n t he char t had t o be t aken
f r oml ast year
'
s br ochur e.
PREMI ER TUBE SETS
Reynol ds 753 - An ul t r al i ght wei ght t ube set t hat
i s heat t r eat ed. I t i s onl y sol d t o bui l der s
cer t i f i ed by Reynol ds. These bui l der s must
submi t a sampl e of t hei r wor k f or dest r uct i on
t est i ng.
Tange Pr est i ge - A speci al heat t r eat ed t ubi ng
wi t h ext r emel y hi gh t ensi l e st r engt h. I t can be
or der ed wi t h ul t r al i ght specs or i n t he same
specs as Tange 1, 2, 3, 4 or 5.
Col umbus SLX - Thi s i s a l i ght wei ght t ube set
t hat has i nt er nal spl i nes at t he bot t ombr acket
end of t he seat t ube, down t ube, and chai nst ays.
I shi wat a 015 - Thi s i s pr obabl y t he l i ght est
t ubi ng set made.
2- 60
THE PATEREK MANUAL FOR BICYCLE FRAMEBUILDERS
THE PATEREK MANUAL FOR BICYCLE FRAMEBUILDERS
THE PATEREK MANUAL FOR BICYCLE
FRAMEBUILDERS
THE PATEREK
MANUAL FOR BICYCLE FRAMEBUILDERS
2-66
FRAMEBUI LDER' S CHECKLI ST
The f ol l owi ng i s a det ai l ed st ep- by- - st ep checkl i st
t o be used by t he begi nni ng f r amebui l der . I t out l i nes
ever y st ep f r omt he begi nni ng t o t he end of cust om
f r ame const r uct i on. Thi s l i st ser ves t wo pur poses:
1 - The bui l der wi l l not have pr obl ems wi t h
acci dent al l y ski ppi ng a pr ocess t hat shoul d
have been done.
2 - The f r amebui l der wi l l be awar e of al l pr ocesses
necessar y t o bui l d a cust omf r ame. By usi ng
t hi s l i st t he bui l der wi l l never have t o say,
"Oh no! I f or got such and such! " or
"
Gee, I
never knew you had t o do t hat . "
Even t he mor e exper i enced f r amebui l der wi l l benef i t
f r omt hi s checkl i st . I t has t aken me si x year s of
f r amebui l di ng, Machi ne school and t he t eachi ng of
numer ous peopl e how t o bui l d f r ames t o be abl e t o
compi l e a cl ear and conci se l i st such as t hi s. Ther e
ar e i t ems of i nt er est whi ch I have i ncl uded i n t hi s
l i st whi ch I have pi cked up by t our i ng t en bi cycl e
f act or i es i n t he U. S. and Eur ope and t al ki ng f or many
hour s wi t h at l east a dozen ot her bui l der s.
si ncer el y doubt i f many ot her f r amebui l der s have had
such exposur e and ar e wi l l i ng t o pass t hi s exposur e on.
Thi s l i st i s set up si mi l ar l y t o t hose used by
machi ne school t eacher s. A pai r of bl anks i s pr ovi ded
i n t he l ef t hand mar gi n f or each st ep. The f i r st bl ank
( CO. ) i s t o be checked of f when t he st ep i s compl et ed.
The second bl ank ( I N. ) i s t o be checked of f when t he
bui l der or t eacher i nspect s t he st ep f or qual i t y,
t ol er ances and al i gnment . Af t er bot h bl anks ar e
checked of f t he bui l der woul d cont i nue on wi t h t he next
st ep.
Do not pr oceed wi t h t hi s checkl i st unt i l you have
r ead t he f r ame geomet r y sect i on.
I mmedi at el y f ol l owi ng t he f r amebui l der
'
s checkl i st
i s an ext ensi ve pi ct ur e st or y. Thi s pi ct ur e st or y can
be r ef er r ed t o at any t i me whi l e goi ng t hr ough t he
checkl i st by usi ng t he cr oss r ef er ence number s gi ven.
Toget her , t he checkl i st and pi ct ur e st or y shoul d
t hor oughl y answer al l quest i ons.
3- 1
3 - 2
1. THE DRAWI NG - Lugs and cr own must be
CO. I N. pur chased by t hi s t i me.
1. Mount a pi ece of paper measur i ng
30" x 30" on a dr awi ng boar d.
( See Fi g. 1)
2. Dr aw a hor i zont al cent er l i ne
about 15cmup f r omt he bot t omof
paper . Thi s i s t he cent er l i ne of
t he axl es and i s t he r ef er ence
poi nt f or l evel ness.
3. Cal cul at e t he amount of bot t om
br acket dr op necessar y and dr aw
anot her hor i zont al cent er l i ne
t hat di st ance bel ow t he f i r st
l i ne. Thi s i s t he cent er l i ne
t hat goes t hr ough t he bot t om
br acket .
4. Fi nd a poi nt on t he bot t om
br acket cent er l i ne about 20cm
f r omt he r i ght edge of t he paper .
At t hi s poi nt scr i be t wo
concent r i c ci r cl es 1 3/ 8" and 1
5/ 8" i n di amet er . Thi s i s t he
bot t ombr acket shel l .
5. Cal cul at e t he seat t ube angl e
t hat wi l l be used and dr aw a
cent er l i ne up out of t he bot t om
br acket cent er at t hat angl e.
( Thi s l i ne shoul d poi nt sl i ght l y
t o t he r i ght as i t r i ses out of
t he bot t ombr acket . ) Thi s i s t he
cent er l i ne f or t he seat t ube.
6. Dr aw t wo l i nes par al l el t o t hi s
l i ne. One l i ne on each si de and
each 9/ 16" away f r omt he
cent er l i ne. The 1 1/ 8" di amet er
seat t ube has j ust been dr awn.
7. Cal cul at e t he l engt h of t he seat
t ube and mar k a poi nt on t he
upper por t i on of t he seat t ube
cent er l i ne exact l y t hi s di st ance
f r omt he cent er of t he bot t om
br acket shel l . Dr aw a hor i zont al
cent er l i ne acr oss t he paper t hat
i nt er cept s t hat poi nt . The
cent er l i ne of t he t op t ube has
j ust been dr awn.
3- 3
CO. I N.
8. Dr aw t wo hor i zont al l i nes
par al l el t o t he t op t ube
cent er l i ne, one wi l l be 1/ 2"
above i t and t he ot her 1/ 2
"
bel ow
i t . The t op t ube has j ust been
dr awn.
9. Cal cul at e t he t op t ube l engt h.
St ar t at t he poi nt wher e t he t op
t ube and seat t ube cent er l i nes
meet . Fr omt hat poi nt and movi ng
t o t he l ef t , mar k a poi nt on t he
t op t ube cent er l i ne at t he pr oper
l engt h f or t he t op t ube. The
head t ube cent er poi nt has j ust
been l ocat ed.
10. Cal cul at e t he head t ube angl e.
Dr op a cent er l i ne f r omt he head
t ube cent er poi nt downwar d at
t hat angl e. ( Thi s l i ne goes
sl i ght l y t o t he l ef t as i t goes
downwar d. ) The head t ube
cent er l i ne has j ust been dr awn
i n.
11. Dr aw a pai r of l i nes par al l el t o
t he head t ube cent er l i ne, one
5/ 8
"
on one si de of i t and t he
ot her 5/ 8
"
on t he ot her si de.
The head t ube has now been dr awn.
12. Cal cul at e t he f or k r ake. Dr aw a
cent er l i ne par al l el t o t he head
t ube cent er l i ne. Thi s l i ne wi l l
be t o t he l ef t of t he head t ube
cent er l i ne i n t he amount of t he
r ake t hat wi l l be used. The
poi nt at whi ch t hi s new l i ne
cr osses t he axl e cent er l i ne i s
t he cent er of t he f r ont axl e.
13. Dr op down t o t he f r ont axl e
cent er . ( Thi s i s t he new
r ef er ence poi nt t o f i ni sh t he
r est of t he dr awi ng. ) Usi ng t he
f r ont axl e cent er st r i ke an ar c
wi t h t he r adi us of t he wheel si ze
t o be used. Thi s ar c must cr oss
t he head t ube cent er l i ne. Thi s
i s t he poi nt at whi ch t he t op of
t he t i r e passes bet ween t he f or k
bl ades and shoul d be l abel ed "t op
of t i r e".
3- 4
CO. I N.
14. Cal cul at e t he amount of
cl ear ance desi r ed bet ween t he t op
of t he t i r e and t he bot t omof t he
cr own. That di st ance shoul d be
f ound al ong t he f r ont edge of t he
head t ube by measur i ng up f r om
t he t op of t he t i r e and mar ki ng
i t on t he f r ont edge of t he head
t ube. Dr aw a l i ne t hr ough t hat
poi nt per pendi cul ar t o t he head
t ube cent er l i ne. Label t hi s
"Bot t omof cr own".
15. Measur e t he t hi ckness of t he
cr own t hat wi l l be used and mar k
anot her poi nt on t he f r ont edge
of t he head t ube t hat di st ance
above t he pr evi ous l i ne. Agai n
dr aw a l i ne t hr ough t hi s poi nt
per pendi cul ar t o t he head t ube
cent er l i ne. Label t hi s l i ne "Top
of cr own and bot t omof headset ".
( See Fi g. 2)
16. Locat e anot her poi nt on t he f r ont
edge of t he head t ube 14mmup
f r omt he pr evi ous l i ne. Agai n
dr aw a l i ne t hr ough t hi s poi nt
per pendi cul ar t o t he head t ube
cent er l i ne. Label t hi s l i ne "Top
of t he headset and bot t omof t he
head t ube
"
. ( See Fi g. 3)
17. Cal cul at e t he HEAD TUBE/ DOWN TUBE
I NTERCEPT POI NT. Now move t o t he
back edge of t he head t ube and
measur e up f r omt he pr evi ous l i ne
t o t he head t ube/ down t ube
i nt er cept poi nt and mar k t hat
poi nt . ( See Fi g. 4)
18. Locat e t he down t ube by usi ng t he
f r ame desi gner ' s st r ai ght edge
descr i bed i n t he Fi xt ur es
sect i on. Thi s can be done by
put t i ng t he cent er not ch of t he
st r ai ght edge di r ect l y on t he
cent er of t he bot t ombr acket and
l ayi ng bot t omedge of t he
st r ai ght edge agai nst t he head
t ube/ down t ube i nt er cept poi nt .
The st r ai ght edge i s now l yi ng
exact l y wher e t he down t ube i s
supposed t o be. Dr aw t he down
t ube by scr i bi ng l i nes al ong t he
t op and bot t omedges of t he
3- 5
st r ai ght edge.
CO. I N.
19. Mat er i al s can be l i st ed di r ect l y
on t he dr awi ng as wel l as on t he
Fr ameset or der f or mpr ovi ded i n
t he Fr amebui l der ' s l abor and
pr i ce schedul e. ( See Fi g. 5)
20. The f r ame speci f i cat i ons can al so
be l i st ed di r ect l y on t he dr awi ng
as wel l as on t he Fr ameset Or der
For m pr ovi ded i n t he
Fr amebui l der
'
s Labor and Pr i ce
Schedul e. ( See Fi g. 5)
21. I f wor ki ng on mor e t han one bi ke
f r ame at once, wr i t e t he
cust omer ' s name i n bi g l et t er s
wi t h bl ack magi c mar ker i n t he
mi ddl e of t he dr awi ng.
22. The dr awi ng may now be
t r ansf er r ed t o a f l at wor ki ng
sur f ace and t aped down. Thi s
sur f ace shoul d ei t her be a st one
sur f ace pl at e or a pi ece of
bl anchar d gr ound st eel at l east
3/ 4" t hi ck.
I I . GENERAL PREPARATI ON - - The t ube set ,
dr opout s, bot t ombr acket shel l ,
l ugs, and f or k cr own shoul d have
been pur chased by t hi s t i me.
( See Fi gs. 6, 7, & 8)
1. Reamt he i nsi de di amet er s of t he
l ugs f or a pr oper f i t wi t h t he
cor r espondi ng f r ame t ubes. A
pr oper f i t f or a si l ver br azed
j oi nt shoul d have about . 004" of
cl ear ance. Thi s wi l l be a
sl i ght l y sl oppy f i t . Thi s
pr ocedur e can be done wi t h a
combi nat i on of an 8" hal f r ound
f i l e and a hi gh speed di e gr i nder
wi t h cyl i ndr i cal st one. ( See
Fi gs. 22 & 23)
2. Reamt he i nsi de di amet er of t he
bot t ombr acket shel l wher e t he
down and seat t ubes ar e i nser t ed.
St r i ve f or t he same f i t as wi t h
t he l ugs. When cl ampi ng t he
bot t ombr acket shel l i n a vi ce
make sur e t o use sof t j aws i n t he
vi se so as not t o damage t he
f aces or any of t he t hr eads.
CO. I N.
( The chai nst ay or i f i ces wi l l be
r eamed l at er . ) ( See Fi g. 22 & 23)
3. Reamt he f or k cr own f or t he
pr oper f i t wi t h t he st eer i ng
col umn. Thi s can be done by
car ef ul l y cl ampi ng t he cr own i n
t he sof t j aws of t he vi se and
r unni ng a #28 Chadwi ck adj ust abl e
hand r eamer t hr ough t he hol e.
( See Fi g. 29& 30)
4. Fi l e and sand t he out si de edges
of t he l ugs, f or k cr own, and
bot t om br acket shel l . Al l
def or mi t i es, bur r s,
i r r egul ar i t i es, and f or mi ng mar ks
shoul d be r emoved dur i ng t hi s
pr ocedur e. Do not t ouch t he
bot t ombr acket f aces, t he f or k
cr own r ace seat or t he head set
seat s on t he l ugs at t hi s t i me!
I t i s not necessar y t o do
anyt hi ng t o t he t op sur f ace of
t he seat l ug at t hi s t i me ei t her .
To pr oduce a hi gh qual i t y cust om
f r ame set expect t o spend f our or
f i ve hour s on t hi s st ep al one.
( See Fi gs. 24 - 28)
5. I f t he f or k bl ades ar e not
pr ebent , t hey must be bent t o t he
cor r ect amount of r ake. When
bendi ng bl ades, bend t he f i r st
one t o specs and bend t he second
t o mat ch. They can be checked
f or how wel l t hey mat ch by
checki ng t he hei ght of t hei r ar c
on t he sur f ace pl at e wi t h a
hei ght gauge. Layi ng t hemon t he
dr awi ng t o check how wel l t hey
mat ch t he desi r ed r ake shoul d be
done t oo. Thi s i s t r i cky wor k
and t he begi nner shoul d pr obabl y
opt f or or der i ng pr ebent bl ades
or f i ndi ng an exper i enced bui l der
who wi l l do t he bendi ng. When
t he bl ades ar e bent , t he ar c of
t he bend must l i e i n t he same
pl ane as f l at t ened oval at t he
t op of t he f or k bl ade! ! ! I f t hi s
i s not accompl i shed, t he f or k
bl ades wi l l have f or k swoop and
wi l l not even come cl ose t o
mat chi ng each ot her i n
appear ance. Thi s par t i cul ar
3- 7
CO. I N.
pr obl emwi l l be a sour ce of
const ant annoyance t o t he r i der
as t hi s i s exact l y wher e t he
r i der i s l ooki ng a l ot of t he
t i me. ( See Fi gs. 31, 32, & 33)
6. I f t he f or k bl ades do not al r eady
have not ches f or t he dr opout s t o
f i t i nt o, t hey must be cut and
f i l ed. These not ches must al so
l i e i n t he same pl ane as t he
f l at t ened oval at t he t op of t he
bl ade. The not ches shoul d be cut
about a 6mmdeep and t he wi dt h
of t he not ches shoul d be
car ef ul l y mat ched t o t he dr opout s
bei ng used. Af t er cut t i ng bot h
not ches and f i t t i ng bot h dr opout s
i npl ace, l i neupbot h
bl ade/ dr opout set s and si ght
acr oss t hemt o make sur e t he
dr opout s ar e not cocked
di f f er ent l y f r omeach ot her . I f
t hat i s t he case, f i l e one of t he
not ches t o cor r ect t hi s pr obl em.
Af t er t he dr opout s have been
f i t t ed, f i l e a t i ny ni ck at t he
t op of one dr opout and t he t op of
i t s mat chi ng bl ade so as not t o
get t hemswi t ched ar ound wi t h t he
ot her set . ( See Fi g. 34 t o 39)
7. I f t he f or k bl ades have domed
___
ends go on t o st ep 8. I f not ,
t he t i ps of t he bl ades shoul d be
scal l oped out f or l ooks as wel l
as obt ai ni ng good cl ear ance
ar ound t he ar ea of t he f r ont
axl e.
8. Repeat al l of st ep 6 f or t he
chai nst ays and r ear dr opout s.
( See Fi g. 34- 39)
9. I f t he chai nst ays do not have
domed ends, r epeat st ep 7 f or t he
chai nst ays.
10. A 3cml ong f l at shoul d be f i l ed
on t he i nsi de f ace of t he r i ght
si de chai nst ay wher e i t meet s t he
dr opout . Thi s i s t o al l ow f or
cl ear ance bet ween t he chai n and
t he chai nst ay. ( See ar r ow, Fi g.
134)
3- 8
CO. I N.
11. Mi t er t he but t ed end of t he seat
t ube wher e i t f i t s i nt o t he
bot t ombr acket shel l . The best
way t o f i nd t he but t ed end of t he
seat t ube i s t o f i nd whi ch end a
27. 2mmseat post wi l l easi l y f i t
i nt o. The ot her end i s t he
but t ed end. ( Wi t h Reynol ds, t he
but t ed end i s t he end st amped
wi t h t he name and gauge of t he
t ubi ng. ) Wr ap t he non- but t ed end
wi t h a r i ng of maski ng t ape so as
not t o get conf used l at er on.
Mar ki ng f or mi t er i ng can be done
by i nser t i ng t he but t ed end of
t he seat t ube i nt o t he
cor r espondi ng hol e of t he bot t om
br acket shel l so i t pr ot r udes
i nt o t he shel l at l east 3/ 4". A
car bi de scr i be can t hen be used
t o scr i be a l i ne wher e excess can
be f i l ed away so t her e wi l l be a
f l ush f i t i nsi de t he bot t om
br acket shel l . The mi t er can be
r oughed i n wi t h a gr i ndi ng wheel
and cl eaned up wi t h a f i l e.
Dur i ng t hi s pr ocedur e, t he t ube
shoul d ei t her be hel d i n a Par k
cl amp or a pai r of al umi numor
wooden Fr amebui l der ' s t ube
cl amps. ( See Fi xt ur es. ) ( See
Fi gs. 9, 10, 14, 15 & 21)
12. Mi t er t he end of t he down t ube
wher e i t hi t s t he backsi de of t he
head t ube. ( I t wi l l be mi t er ed
t o an angl e of 57 t o 62 degr ees. )
I n t he case of Reynol ds, t he end
bei ng mi t er ed now shoul d be t he
"shor t but t .
"
Thi s i s t he end
st amped wi t h t he name and gauge.
I n t he case of Col umbus, be sur e
t o pur chase t he A, B, or C set t o
mat ch t he si ze of t he f r ame bei ng
bui l t and cut ei t her end.
Mar ki ng f or mi t er i ng can be done
by i nser t i ng t he shor t but t ed end
of t he down t ube i nt o t he
cor r espondi ng hol e i n t he bot t om
head l ug. The t ube shoul d
pr ot r ude t o about t he cent er of
t he l ug. Wi t h a car bi de scr i be,
3- 9
CO. I N.
scr i be a l i ne ar ound t he t ube
wher e t he excess wi l l be cut of f .
The mi t er can be r oughed i n on a
gr i ndi ng wheel and t he f i ner wor k
can be done wi t h a f i l e. Agai n
t he t ube shoul d be hel d i n a Par k
cl amp or t ubi ng bl ocks. The
mi t er shoul d be checked wi t h
t hr ee devi ces as f ol l ows:
1. The angl e of t he mi t er must
be checked wi t h a bevel
pr ot r act or f r equent l y dur i ng
mi t er i ng. The cor r ect angl e
may be t aken of f t he dr awi ng
wi t h t he pr ot r act or . ( I f
t hi s angl e i s not bet ween 57
and 62 degr ees, somet hi ng i s
wr ong. )
2. The pr oper f i t must be
checked wi t h a pi ece of head
t ube. The head t ube must
nest l e i nt o t he mi t er wi t h an
absol ut e mi ni mumof l i ght
showi ng t hr ough bet ween t he
t wo t ubes.
3. To see i f t he mi t er f al l s
di r ect l y al ong t he cent er l i ne
of t he down t ube, a
machi ni st ' s squar e can be
l ai d acr oss t he t wo peaks of
t he mi t er . Bot h peaks shoul d
be t he same hei ght . ( See
Fi gs. 11, 13, 14, 15, 16, 17,
18, 19, 20)
Nor mal l y, i n t he bi cycl e
i ndust r y, mi t er i ng i s done on a
$10, 000. 00 Br i dgepor t mi l l . A
hundr ed t ubes wi l l be mi t er ed i n
one r un and i t t akes about 30 t o
45 seconds t o do each one. Of
cour se, t hi s i s out of t he
quest i on f or t he aver age cust om
f r amebui l der . So t he cust om
bui l der must do t hi s by hand.
Af t er pr act i ce t hi s pr ocedur e can
be execut ed i n about 15 mi nut es.
13. Mi t er t he shor t but t ed end of t he
t op t ube wher e i t meet s t he
backsi de of t he head t ube. Thi s
wi l l be mi t er ed at about 72 t o 75
3- 10
CO. I N. degr ees. Agai n t he angl e can be
t aken di r ect l y of f t he dr awi ng.
Asi de f r omt he angl e necessar y,
t he pr ocedur e i s i dent i cal t o t he
mi t er i ng of t he downt ube. I t i s
ver y i mpor t ant t o wr ap a pi ece of
maski ng t ape ar ound t he t op t ube
cl ose t o t he shor t but t ed end t o
be abl e t o r emember whi ch end was
mi t er ed f i r st . I f t hi s i s not
done, i t i s possi bl e t o put t he
t op t ube i n backwar ds f r omhow i t
was mi t er ed. Thi s i s because t he
r adi i of t he mi t er s at bot h ends
of t he t op t ube ar e t oo cl ose t o
each ot her t o be abl e t o t el l t he
di f f er ence bet ween t hemeasi l y.
However , t he mi t er s ar e di f f er ent
enough t o t hr ow of f t he f r ont
t r i angl e by . 5mm f r om t he
dr awi ng. ( See Fi gs, 12- 20)
14. I f eyel et s ar e not desi r ed, t hey
may be cut of f of t he dr opout s at
t hi s t i me.
15. I f st amped l ugs ar e bei ng used,
i t i s a good i dea, at t hi s t i me,
t o br aze i n a l i t t l e sl eeve t o
st r engt hen t he bi nder assembl y i n
t he seat l ug. I t shoul d be done
wi t h br ass so i t won' t mel t when
f i nal si l ver br azi ng i s done on
t he j oi nt l at er .
16. I f any cut out s ar e desi r ed i n t he
l ugs or dr opout s or bot t om
br acket shel l , t hey shoul d be
f ashi oned at t hi s t i me.
I I I . THE FRONT TRIANGLE - At t hi s poi nt no
si l ver br azi ng has been done and no
mor e t han one end of each t ube has
been wor ked wi t h. Mat er i al s on hand
at t hi s poi nt shoul d i ncl ude t he
pr epped f r ameset , 2 oz. of Easy- Fl o
30 si l ver br azi ng al l oy, wat er
sol ubl e si l ver br azi ng f l ux, mi l d HC1
aci d sol ut i on, cour se/ medi um/ f i ne
emer y cl ot h st r i ps.
1. Pr epar e t he bot t ombr acket shel l
and t he but t ed end of t he seat
t ube f or si l ver br azi ng. Thi s i s
done by t hor oughl y cl eani ng bot h
sur f aces of t he j oi nt wi t h 150
3- 11

Ih Ic I 45-55%A .
H h p c I f
] w w k O w
p c I f w
c Iw k. Ih f wh ch
w h v Ih c cIf w
ch cI I c Ih hI
I Ihp p I .
gr i t emer y cl ot h and/ or a wi r e
wheel . The pi eces can al so be
washed wi t h an al kal i ne cl eaner
and di pped i n and scr ubbed wi t h a
mi l d HC1 aci d sol ut i on. They
shoul d be i mmedi at el y r i nsed wi t h
wat er and bl own dr y wi t h a
compr essor . The most i mpor t ant
f act or i n si l ver br azi ng i s
cl eanl i ness. The pi eces shoul d
be t ot al l y devoi d of any gr ease,
oi l , met al t r eat ment or f or ei gn
par t i cl es of any sor t . Do not
t ouch t hemaf t er t hey have been
pr epar ed f or si l ver br azi ng.
Si l ver br azi ng shoul d be done
wi t hi n a coupl e hour s of t hi s
pr epar at i on as r ust set s i n
qui ckl y on cl eaned unt r eat ed
met al l i ke t hi s. ( See Fi g. 40)
WARNI NG - I f t he bui l der
chooses t o use a mi l d HC1
aci d sol ut i on f or cl ean- up
pur poses, i t shoul d be done
wi t h t he best vent i l at i on
possi bl e and whi l e wear i ng
heavy dut y r ubber gl oves.
The aci d vapor pr oduced by
t hi s cl eani ng pr ocess can
cause per manent l ung damage
and any aci d get t i ng i nt o
open cut s wi l l eat away at
body t i ssues f or sever al days
bef or e bei ng neut r al i zed by
t he body. When not i n use,
t he sol ut i on shoul d be
cover ed or seal ed. I f
al l owed t o evapor at e i nt o t he
ai r , even a l i ght
concent r at i on i n t he
at mospher e wi l l cause
anyt hi ng made of st eel t o
r ust at a gr eat l y accel er at ed
r at e. I n t he case of
cl eani ng up si l ver br azed
j oi nt s af t er t he j oi nt s ar e
f i ni shed, t he aci d must be
t hor oughl y r i nsed of f and
bl own cl ean. The smal l est
amount of aci d r esi due can
dest r oy a si l ver br azed j oi nt
i n j ust a f ew days t i me.
Aci d r esi due l ef t i nsi de t he
t ubes can eat r i ght t hr ough
t he wal l s of t he t ubi ng i n a
3- 12
CO. I N. mat t er of mont hs. I f usi ng
HC1 aci d sol ut i ons, f ol l ow
al l r ecommendat i ons and
caut i ons l i st ed i n t hi s
publ i cat i on! ( Sno- Bol t oi l et
bowl cl eaner i s t he best and
most r eadi l y accessi bl e
sour ce of an HC1 aci d
sol ut i on. )
2. Appl y f l ux gener ousl y t o bot h
sur f aces t o be j oi ned and
assembl e t hem. Fl ux shoul d be
appl i ed shor t l y af t er cl ean- up t o
keep sur f ace r ust f r omst ar t i ng.
Use pl ent y of f l ux as a l ot of i t
wi l l dr i p of f dur i ng t he
pr e- heat . ( See Fi g. 41)
WARNI NG - Si l ver sol der f l ux
cont ai ns f l uor i des and i s
aci di c. I t i s ext r emel y
i r r i t at i ng t o t he eyes,
mucous membr anes, and any
open sor es. Do not l et t he
f l ux come i n cont act wi t h any
of t hese ar eas. Wash your
hands f r equent l y whi l e usi ng
t hi s f l ux and speak t o your
doct or about f i r st ai d
pr ocedur es bef or e an acci dent
occur s. Read al l caut i ons on
t he si de of t he cont ai ner and
keep out of r each of
chi l dr en.
3. Fast en t he seat t ube and bot t om
br acket l i ght l y i nt o t he bot t om
br acket j i g. ( Make sur e t he seat
t ube ent er s t he cent er hol e. ) To
be sur e t he seat t ube comes out
of t he bot t ombr acket squar el y,
r ot at e t he bot t ombr acket one way
t hen t he ot her . Fi nd a posi t i on
hal f way bet ween t he t wo
ext r emes. Now cl amp t he bot t om
br acket t i ght l y i n t he j i g.
4. Make sur e t he seat t ube i s f l ush
wi t h t he i nsi de of t he bot t om
br acket shel l and t he mi t er i s
not r ot at ed at al l . Now cl amp
down t he seat t ube i n t he j i g.
5. The j oi nt i s now r eady f or si l ver
br azi ng. Bot t ombr acket pr eheat
3- 13
i s i mpor t ant . I t wi l l t ake
appr oxi mat el y 5 t o 7 mi nut es t o
heat up t he j oi nt t o t he r i ght
t emper at ur e wi t h oxy- acet yl ene.
Whi l e heat i ng, have t he si l ver i n
one hand and r eady t o scoop up
f l ux t hat f al l s and gl op i t back
ont o t he j oi nt . Save as much
f l ux as possi bl e. Use t hi s
pr eheat t i me t o make sur e t he
whol e j oi nt i s evenl y cover ed
wi t h f l ux. Use t he si l ver t o
smear t he f l ux ar ound. Keep t he
f l ame movi ng at al l t i mes or t he
r i sk of over heat i ng i ncr eases
gr eat l y. I n t he case of
appr oachi ng t he l evel of
over heat i ng, pul l back wi t h t he
f l ame f or a coupl e of seconds.
( A sl i ght l y car bur i zi ng f l ame
shoul d be used. ) The f l ux shoul d
be used as a t emper at ur e
i ndi cat or . I t wi l l be appl i ed as
a wet past e. As i t heat s up i t
wi l l t ur n i nt o a dr y cr ust . As
i t heat s up mor e i t wi l l appear
t o be a wet f l ui d wi t h a l ot of
bubbl i ng act i vi t y t aki ng pl ace.
Wat ch t he bubbl es. As t he f l ux
get s t o t he r i ght t emper at ur e,
t he bubbl es wi l l get smal l er and
smal l er . When t he bubbl es get so
smal l t hat t hey seemr eady t o
di sappear al t oget her , t he j oi nt
i s hot enough t o st ar t si l ver
br azi ng. ( I t i s not possi bl e t o
get t he whol e j oi nt hot enough
al l at t he same t i me wi t hout a
hear t h pr ocess so as you wor k
ar ound t he j oi nt wi t h t he si l ver ,
j ust wat ch t hose bubbl es as you
go. ) The best pr ocedur e i s t o
br aze t he t i ps "peaks" f i r st and
t hen do t he
"
val l eys" of t he
j oi nt . By l ooki ng i nsi de t he
bot t ombr acket shel l t he bui l der
can see i f good penet r at i on i s
bei ng accompl i shed by l ooki ng f or
t he si l ver as i t comes t hr ough.
( See Fi g. 42)
WARNING Ti nt ed gl asses
shoul d al ways be wor n whi l e
usi ng t he t or ch. However ,
use of t i nt ed l enses
i ncr eases t he danger of
over heat i ng. The t i nt of t he
3- 14
CO. I N. l enses wi l l change t he col or
per cept i on of t he bui l der
enough t o not be abl e t o
det ect mi l d over heat i ng.
Whi l e si l ver br azi ng i n a
wel l l i t r oom, t he bui l der
shoul d not even be abl e t o
pi ck out t he l east amount of
r eddi sh col or of t he met al .
I n a ver y dar k r ooma ver y
dul l r ed can be per cei ved at
si l ver br azi ng t emper at ur es.
( Do not conf use t he r eddi sh
col or of hot f l ux wi t h t he
met al . Somet i mes t he f l ux
wi l l become r ed whi l e t he
met al i s st i l l t he r i ght
t emper at ur e. Fl ux wi l l br eak
down and get a muddy
appear ance i f i t i s
over heat ed. ) I f you choose
t o wor k wi t hout t i nt ed
l enses, you do so at your own
r i sk.
6. Af t er t he wor k has cool ed
suf f i ci ent l y, i t can be r emoved
f r omt he j i g. I t shoul d t hen be
soaked i n hot wat er l ong enough
t o r emove t he f l ux. Do not
i mmer se a hot j oi nt i n wat er .
Heat di st or t i on wi l l be gr eat l y
i ncr eased by doi ng t hi s. Whi l e
soaki ng t he j oi nt , t he f l ux can
be chi pped of f wi t h a shar p
i mpl ement t o speed up t he
pr ocess. Do not chi p of f pi eces
of f l ux wi t h your f i nger s! Those
pi eces of f l ux ar e as shar p as
shat t er ed gl ass! I f HC1 aci d
cl ean- up i s done, t hor oughl y
r i nse and bl ow dr y t he j oi nt .
7. Cl amp t he seat t ube i n t he Par k
cl amp or bl ocks. The bot t om
br acket shoul d now be r et apped
wi t h Campagnol o t ool #721 or
equi val ent . ( See Sut her l and' s
Manual f or pr oper use of bot t om
br acket t aps. ) ( See Fi g. 43)
8. Whi l e st i l l cl amped up t he bot t om
br acket shel l shoul d be f aced
wi t h Campagnol o t ool #725 or
equi val ent . ( See Sut her l and' s
Manual f or t he pr oper pr ocedur e
3- 15
CO. I N. f or bot t ombr acket f aci ng. ) ( See
Fi gs. 44 & 45) .
9. The j oi nt shoul d now be checked
f or def l ect i on due t o heat
di st or t i on. Thi s can be done by
cl ampi ng t he t op of t he seat t ube
and l ayi ng t he bot t ombr acket
mi cr omet er agai nst t he f aces of
bot t ombr acket on each si de. One
hal f of t he di f f er ence bet ween
t he t wo si des i s t he amount of
er r or . A di f f er ence i n t he
r eadi ngs of mor e t han 1mmover a
span of 50cmi s unaccept abl e. I f
col d set t i ng i s necessar y, t he
bot t ombr acket f aces shoul d be
cl amped t i ght l y i n t he sof t j aws
of t he vi se and t he j oi nt must be
bent t o specs. I f doi ng t hi s
wi t h SL t ubi ng or l i ght er , i nser t
a 1
"
di amet er st eel r od down t he
ent i r e l engt h of t he seat t ube
f or r ei nf or cement bef or ecol d
set t i ng. ( Col d set t i ng i s a
necessar y evi l of f r ame bui l di ng
and wi l l be necessar y on near l y
75%of al l t he j oi nt s i n t he
f r ame. ) ( See Fi gs. 46 & 47)
10. A f i nal cosmet i c cl ean- up shoul d
now be done bef or e goi ng on t o
t he next j oi nt . Unsi ght l y
spl ot ches of si l ver can be
r emoved wi t h j ewel er s' f i l es and
120 gr i t emer y cl ot h. ( See Fi gs.
48 & 49)
11. Cl ean- up one end of t he head t ube
and t he bot t omhead l ug and pr ep
t hemf or si l ver br azi ng. ( See
Fi g. 50)
12. Appl y f l ux.
13. Pl ace t he bot t omhead l ug on t he
end of t he head t ube wi t h about
1mmpr ot r udi ng t hr ough t he bot t om
of t he l ug. Make sur e t he i nner
sur f ace of t he l ug i s t i ght
agai nst t he back f ace of t he head
t ube.
14. Li ght l y cl amp t he head t ube i n
t he sof t j aws of t he vi se so t hat
3- 16
CO. I N. t he l ug i s sever al cent i met er s
away f r omt he vi se and t he poi nt s
of t he l ug st i cki ng st r ai ght up
i n t he ai r . ( See Fi g. 51)
15. Si l ver br aze t he j oi nt now.
Pr eheat wi l l be much f ast er on
t hi s pi ece. Add si l ver t o t he
1mmof head t ube st i cki ng past
t he bot t omof t he l ug and dr aw i t
t hr ough t o t he ot her si de. Mor e
si l ver can be added t o t he back
si de of t he head t ube r i ght above
t he l ug and dr awn down t hr ough i n
t heot her di r ect i on. Af t er
f i ni shi ng t he j oi nt , i nspect i t
f or good penet r at i on. Not e i f
si l ver has come t hr ough t he ar ea
wher e t he down t ube wi l l be
i nser t ed. ( See Fi g. 51)
16. Cl ean- up ( St ep 6)
17. An ai r expansi on hol e must be
dr i l l ed at t he cent er poi nt of
wher e t he down t ube wi l l
i nt er cept t he back of t he head
t ube. ( I n ot her wor ds, r i ght
bet ween t he poi nt s of t he l ug and
i nt o t he head t ube. ) A l ar ge
hol e i s desi r abl e. Thi s wi l l
al l ow f or easy f l ushi ng of t he
t ubes dur i ng t he f i nal met al
t r eat ment . ( dr i l l t hi s hol e 1/ 2"
i n di amet er . )
18. Bef or e si l ver br azi ng t he down
t ube i nt o t he bot t omhead l ug,
t he angl e of t hat j oi nt must be
checked. I f usi ng Henr y J ames
l ugs, t he f i t i s so pr eci se t hat
af t er usi ngal ugwi t h a
desi gnat ed angl e, t he j oi nt
shoul d f al l wi t hi n t ol er ances.
I f usi ng anot her br and of l ug,
some pr ebendi ng of t he l ug wi l l
be necessar y t o be sur e t hat t he
j oi nt wi l l be t he cor r ect angl e.
Bef or e doi ng any of t he necessar y
bendi ng, t he angl e of t he j oi nt
shoul d be checked wi t h t he bevel
pr ot r act or t o see how much
bendi ng i s r equi r ed. Af t er
3- 17
CO. I N. bendi ng t he l ug t o t he pr oper
angl e, i t must be checked agai n
wi t h t he bevel pr ot r act or . I f
t he angl e has been achi eved, t he
j oi nt i s r eady f or si l ver
br azi ng. ( Thi s i s, wi t hout a
doubt , t he most i mpor t ant j oi nt
of t he whol e bi ke. I f t hi s j oi nt
i s of f by any amount , st eer i ng
geomet r y wi l l be af f ect ed as wel l
as t he gener al conf i gur at i on of
t he ent i r e f r ont t r i angl e. ; ( See
Fi g. 52)
19. Cl ean- up t he t op of t he down t ube
and bot t omhead l ug and pr ep t hem
f or si l ver br azi ng.
20. Appl y f l ux.
21. Assembl e par t s and cl amp i n Par k
cl amp or bl ocks so t hat t he head
t ube i s hor i zont al and at about
eye l evel . ( No j i g i s necessar y
f or t hi s j oi nt . ) A l ong 1"
di amet er st eel bar can be put
t hr ough t he head t ube as a
count er bal ance i n or der t o hol d
t he head t ube at t he desi r ed
angl e. ( See Fi g. 53)
22. Af t er t he pr eheat , t ack t he
poi nt s of t he l ug and l et i t cool
f or a f ew mi nut es.
23. Use t he bevel pr ot r act or t o check
t he angl e of t he j oi nt . I f
bendi ng i s necessar y, i nser t 1"
st eel bar s t hr ough t he head t ube
andupt hedownt ube f or
r ei nf or cement . Bend t o specs.
Check wi t h bevel pr ot r act or and
bend mor e i f necessar y. ( See
Fi g. 54)
24. Af t er maki ng sur e t he desi r ed
angl e i s r eached, cont i nue wi t h
t he si l ver br azi ng and f i ni sh up
t he j oi nt .
25. I t may be necessar y t o r epeat
st ep 23 agai n at t hi s poi nt .
26. I f wor ki ng on a sur f ace pl at e,
t he head t ube/ down t ube
3- 18
CO. I N. conf i gur at i on can be suspended
above t he dr awi ng wi t h V- bl ocks
and t he angl e can be checked wi t h
a machi ni st ' s squar e by
t r ansf er r i ng t he l i nes di r ect l y
up t o t he edges of t he t ubes.
( See Fi gs. 55 t o 60)
27. Cl ean up t he j oi nt and r epeat
st ep 10.
28. I nser t t he down t ube i nt o t he
bot t ombr acket and suspend t he
head t ube/ down t ube/ seat t ube
( HT/ DT/ ST) conf i gur at i on above
t he dr awi ng wi t h V- bl ocks. Use a
machi ni st ' s squar e t o get t he
head t ube and down t ube di r ect l y
over t he dr awi ng. Now f i gur e out
wher e t o make a r ough cut at t he
bot t omof t he down t ube so t hat
about 1cm of t ube wi l l be
st i cki ng i nt o and past t he i nsi de
of t he bot t ombr acket shel l .
( See Fi g. 55)
29. Cut t he t ube of f at t he mar k.
30. Agai n suspend t he HT/ DT/ ST
conf i gur at i on above t he dr awi ng
wi t h V- bl ocks. Thi s t i me make
sur e t hat al l t hr ee t ubes ar e
di r ect l y above t he dr awi ng by
usi ng t he machi ni st
'
s squar e t o
t r ansf er l i nes of t he dr awi ng up
t o t he edges of t he t ubes. Some
col d set t i ng may be necessar y t o
achi eve t he cor r ect angl e of t he
down and seat t ubes.
31. When t he f r ame i s i n posi t i on
above t he dr awi ng, measur e t he
di st ance f r omt he t op f r ont of
t he seat t ube t o t he t op f r ont of
t he head t ube. Make not e of t hi s
measur ement . ( See Fi g. 59& 60)
32. Wi t h a car bi de scr i ber , scr i be
f or t he mi t er of t he l ower end of
t he down t ube i nsi de t he bot t om
br acket but do not t ake t he f r ame
of f t he V- bl ocks yet ! ( See Fi g.
56)
33. Wi t h t he scr i ber , scr i be a l i ne
on t he down t ube wher e i t ent er s
3- 19
CO. I N. t he out si de of t he bot t ombr acket
al so. ( See Fi g. 57)
34. Car ef ul l y pi ck up t he f r ame
di st ur bi ng as l i t t l e as possi bl e
and scr i be t he ot her si de of t he
down t ube wher e t he mi t er wi l l be
made.
35. Pul l t he t wo f r ame pi eces apar t
and make a l i t t l e f i l e ni ck wher e
t he down t ube i s ent er i ng t he
out si de of t he bot t ombr acket .
( Same mar k as t he one i n st ep
I I I - 33)
36. Rough i n t he mi t er wi t h t he
gr i ndi ng wheel .
37. Fi ni sh t he mi t er wi t h an 8" hal f
r ound f i l e. ( See Fi g. 58)
38. Cl ean up t he down t ube/ bot t om
br acket j oi nt and pr epar e i t f or
si l ver br azi ng.
39. Appl y f l ux.
- 40. Mount t he seat t ube and bot t om
br acket i n t he bot t ombr acket j i g
as bef or e. ( See Fi g. 61)
41. I nser t t he head t ube i nt o t he
head t ube st abi l i zer bar ( See
Fi xt ur es. ) and i nser t down t ube
i nt o bot t ombr acket shel l whi l e
at t achi ng t he head t ube
st abi l i zi ng bar t o t he bot t om
br acket j i g. ( See Fi g. 61)
42. Fi nd t he t i ny f i l e ni ck i n t he
down t ube and l i ne i t up wi t h t he
poi nt at whi ch t he down t ube
ent er s t he bot t ombr acket shel l .
Tempor ar i l y t i ght en down t he head
t ube st abi l i zi ng bar so t he ni ck
doesn' t move.
43. Dr i l l a smal l hol e t hr ough t he
bot t ombr acket and down t ube t o
i nser t a st eel peg. ( A 4d nai l
or smal l er makes a good peg. )
( See Fi g. 62)
3- 20
CO. I N.
44. Loosen t he head t ube st abi l i zer
bar agai n and make sur e t he
measur ement f r omt he t op f r ont of
t he Seat t ube t o t he t op f r ont of
t he head t ube i s t he same as t he
one t aken i n st ep #31. When t hi s
measur ement i s set cor r ect l y,
t i ght en down t he head t ube
st abi l i zer bar agai n. ( See Fi g.
61)
45. Si l ver br aze t he j oi nt . Thi s i s
a l ong pr eheat agai n due t o t he
mass of t he bot t ombr acket .
( Take your phone of f t he hook f or
a whi l e. ) ( See Fi g. 63)
46. Af t er t he j oi nt has cool ed
suf f i ci ent l y, cl ean up as i n st ep
111- 6.
47. Def l ect i on of t he down t ube
shoul d be checked t he same as i t
was i n st ep 111- 9. ( See Fi gs. 46
& 47)
48. Col d set as necessar y t o be
wi t hi n t he t ol er ances descr i bed
i n st ep #9. I f wor ki ng wi t h
l i ght er t ubi ng, t her e i s a
def i ni t e danger of cr i mpi ng t he
down t ube dur i ng t hi s pr ocedur e.
To saf eguar d agai nst t hi s a down
t ube pr ot ect i ng sheat h can be
pl aced ar ound t he down t ube
bef or e col d set t i ng. ( See
Fi xt ur es. )
49. Check t he measur ement f r omt he
t op f r ont of t he seat t ube t o t he
t op f r ont of t he head t ube.
Dur i ng heat i ng and cool i ng t hi s
measur ement may have been l ost
due t o di st or t i on, expansi on and
cont r act i on. I f col d set t i ng
i s necessar y, i nser t a l ong 1"
di amet er st eel bar down t he seat
t ubeand put t he pr ot ect i ng
sheat h ar ound t he down t ube.
Col d set as needed. ( See Fi gs.
59, 60 & 61)
50. Agai n suspend t he f r ame above t he
dr awi ng wi t h V- bl ocks and check
wi t h a machi ni st ' s squar e t o see
t hat al l t ubes ar e di r ect l y above
3- 21
CO. I N. t he cor r espondi ng l i nes of t he
dr awi ng. I f f ur t her col d bendi ng
i s necessar y, do so. An er r or of
t he t hi ckness of a l i ne i s
accept abl e over a span of 50 or
60 cent i met er s.
51. Whi l e t he f r ame i s st i l l
suspended above t he dr awi ng, f i nd
t he poi nt wher e t he bot t omof t he
t op t ube hi t s t he back si de of
t he head t ube on t he dr awi ng.
Wi t h a machi ni st ' s squar e,
t r ansf er t hi s poi nt up t o t he
cor r espondi ng poi nt on t he back
si de of t he act ual head t ube.
Make a f i l e ni ck at t he poi nt .
( See Fi g. 64 & 65)
52. Fi nd t he poi nt on t he dr awi ng at
whi ch t he bot t omof t he t op t ube
hi t s t he f r ont of t he seat t ube.
Tr ansf er t hi s poi nt up t o t he
act ual seat t ube and make a f i l e
ni ck at t hat poi nt . ( See Fi g.
66)
53. Fi nd t he poi nt on t he dr awi ng
wher e t he cent er l i ne of t he t op
t ube hi t s t he back of t he head
t ube. Tr ansf er t hi s poi nt up t o
t he head t ube and mar k t hat poi nt
wi t h a car bi de scr i be. Thi s wi l l
be t he l ocat i on of an ai r
expansi on hol e. ( See Fi g. 65)
54. Fi nd t he poi nt on t he dr awi ng
wher e t he t op t ube cent er l i ne
hi t s t he f r ont of t he seat t ube.
Tr ansf er t hi s poi nt up t o t he
act ual seat t ube and mar k t hat
poi nt wi t h a car bi de scr i be.
Thi s i s t he l ocat i on f or anot her
ai r expansi on hol e. ( See Fi g.
66)
55. Cl amp t he f r ame i n t he Par k cl amp
or bl ocks and l eave i t t her e t i l l
needed agai n.
56. Fi nd t he di st ance f r omt he poi nt
f ound i n st ep 111- 51 t o t he
poi nt f ound i n st ep 111- 52.
Make not e of t hat measur ement .
( See Fi gs. 67 & 68)
3- 22
CO. I N.
57. Take t he t op t ube and f i nd t he
t op sur f ace of i t . ( The t op head
l ug wi l l be usef ul i n doi ng
t hi s. ) Mar k wi t h a magi c mar ker
on t he pi ece of maski ng t ape
whi ch sur f ace i s t he t op of t he
t op t ube. ( St ep 11- 13 of t he
gener al pr ep had you i nst al l a
pi ece of t ape ar ound t he shor t
but t ed end of t he t op t ube. )
58. Take t he measur ement f r omst ep
111- 56 and t r ansf er i t t o t he t op
sur f ace of t he t op t ube. Make a
f i l e ni ck at t hat poi nt . ( See
Fi g. 69)
59. Cut t he t op t ube 15mml onger t han
i ndi cat ed by t hat mar k. ( See
Fi g. 69)
60. Now use t he seat l ug t o scr i be
wher e t he mi t er wi l l be at t he
seat t ube end of t he t op t ube.
Make sur e t he t op of t he seat l ug
i s on t he t op sur f ace of t he t op
t ube! The scr i be mar k shoul d go
r i ght t hr ough t he f i l e ni ck made
i n st ep 111- 58.
61. Rough i n t he mi t er wi t h t he
gr i ndi ng wheel . ( Don' t f or get
t hat t he mi t er s at bot h ends of
t he t op t ube wi l l be r oughl y
par al l el . I f t hey ar e not
par al l el , somet hi ng i s wr ong! )
To be on t he saf e si de, do t he
r oughi ng wor k about 1mml onger
t han t he f i l e ni ck. ( See Fi g.
70)
62. The mi t er can now be f i ni shed
wi t h t he 8" hal f r ound f i l e.
Thi s i s def i ni t el y t he most
t edi ous j oi nt t o mi t er on t he
ent i r e f r ame. The begi nner can
expect t o t ake 45 mi nut es or mor e
t o do t hi s j ob. Set t he or i gi nal
mi t er ( shor t but t wi t h maski ng
t ape) agai nst t he back si de of
t he head t ube. Make sur e t he
bot t omsur f ace of t he t op t ube
hi t s t he f i l e ni ck on t he back
si de of t he head t ube. Now
car ef ul l y dr op t he back of t he
t op t ube i nt o pl ace agai nst t he
3- 23
CO. I N. seat t ube. At f i r st t he t op t ube
wi l l be near l y 3cmabove t he f i l e
ni ck on t he seat t ube. The mi t er
must now be car ef ul l y and
gr adual l y f i l ed so t hat t he t op
t ube f i nal l y dr ops i nt o pl ace.
The t op t ube must dr op i nt o
pl ace! Thi s cannot be a f or ce
f i t ! ! ! ! A f or ce f i t wi l l t hr ow
of f t he ent i r e geomet r y of t he
f r ont t r i angl e. I t woul d be a
good i dea t o r echeck t he
measur ement f r om st ep 111- 31.
( See Fi gs. 71, 72, & 73)
63. Af t er t he t op t ube i s cut and
mi t er ed t o t he cor r ect l engt h,
i nst al l t he t op head l ug and t he
seat l ug on t he cor r ect ends and
sl i de t hemal l down on t he head
t ube and seat t ube. Put t he
ent i r e f r ont t r i angl e on t he
V- bl ocks above t he dr awi ng. Use
t he Squar e t o get t he f r ame i n
t he r i ght posi t i on. Sl i de t he
t op t ube down t o t he posi t i on i t
shoul d be on t he head and seat
t ubes by usi ng t he squar e. At
t hi s t i me t he machi ni st
'
s squar e
shoul d t r ansf er al l l i nes
di r ect l y up t o al l edges of t he
f r ont t r i angl e. ( Onl y t r ansf er
l i nes up f r omt he i nt er i or of t he
f r ont t r i angl e. You' l l go nut s
t r yi ng t o t r ansf er l i nes up
ar ound t he i nsi de edges of t he
f r ont t r i angl e as wel l as t he
i nsi de edges. ) ( See Fi g. 74)
64. I f al l i nsi de edges of t he
dr awi ng t r ansf er up t o t he f r ame
wi t h t he l east amount of er r or ,
( See 111- 50) t hen make a f i l e
ni ck on t he head t ube wher e t he
t op of t he t op head l ug i s. Then
make anot her f i l e ni ck wher e t he
t op of t he seat l ug i s.
65. Sl i de t he t op t ube of f agai n and
cut t he head t ube 1cml onger t han
t he f i l e ni ck i ndi cat es. Then
cut t he seat t ube 1cml onger t han
necessar y. ( I f t her e i s a spear
poi nt at t he t op of t he seat l ug,
make sur e t o al l ow f or t hat . )
3-24
CO. I N.
66. Pr i ck punch, cent er punch, pi l ot
dr i l l and dr i l l t he ai r expansi on
hol es t hat wer e l ocat ed i n st eps
111- 53 & 111- 54. Agai n 1/ 2"
di amet er hol es wi l l al l ow f or
mor e ef f i ci ent f l ushi ng of t he
t ubesdur i ng t hef i nal aci d
t r eat ment . ( See Fi g. 66)
67. Cl ean and pr ep t he t wo l ugs f or
si l ver br azi ng.
68. Cl ean and pr ep t he t wo ends of
t he t op t ube f or si l ver br azi ng.
69. Cl ean and pr ep t he t ops of t he
head and seat t ubes f or si l ver
br azi ng.
70. Appl y f l ux t o al l sur f aces.
71. Assembl e al l par t s f or f i nal
si l ver br azi ng. Al i gn f i l e
ni cks. ( See Fi g. 75)
72. I nst al l a modi f i ed C- cl amp #2
t o keep t he head l ug f r om
cr eepi ng down t he head t ube.
( See Fi g. 77)
73. I nst al l a modi f i ed C- cl amp #2 t o
keep t he seat l ug f r omcr eepi ng
up t he seat t ube.
74. I nst al l t he modi f i ed bar cl amp t o
make sur e t he seat and head t ubes
come i n cont act wi t h t he ends of
t he t op t ube. Ti ght en i t snugl y.
Don' t t or que i t down! ( See Fi g.
75)
75. I f t he poi nt s of t he l ugs ar e
st i cki ng up, t he modi f i ed C- cl amp
#1 can be used t o hol d t hemdown.
( See Fi g. 76)
76. Si l ver br aze t he seat l ug and
head l ug i n ei t her or der usi ng
t he si l ver br azi ng t echni ques
descr i bed ear l i er . Cl amps can be
r emoved as t hey ar e no l onger
needed. Tr y t o saf eguar d agai nst
i nt er r upt i ons. The begi nner wi l l
be si l ver br azi ng f or over an
hour dur i ng t hi s st ep.
3- 25
CO. I N. WARNING Some t ype of
char coal f i l t er mask shoul d
be wor n dur i ng si l ver
br azi ng. Par t i cul ar l y when
si l ver br azi ng f or l ong
per i ods of t i me. The
f l uor i des i n t he f l ux and t he
cadmi umf umes gi ven of f by
t he si l ver ar e bot h qui t e
har mf ul . I f di zzi ness or
nausea ar e exper i enced dur i ng
si l ver br azi ng get f r esh ai r
i mmedi at el y and cont act a
physi ci an f or any f ur t her
t r eat ment necessar y. Al ways
have good vent i l at i on.
77. Al l ow t he j oi nt s t o cool bef or e
cl eani ng of f t he f l ux wi t h wat er
and aci d. Cl ean i n t he same
manner as pr evi ousl y descr i bed.
78. Gr i nd and f i l e away t he excess
seat t ube pr ot r udi ng t hr ough t he
t op of t he seat l ug. Do t he
f i nal f i l i ng wi t h a hal f r ound
j ewel er s' f i l e.
79. Cl ean up t he seat l ug as
descr i bed i n st ep I I I - 10.
80. Cl ean up t he t op head l ug as
descr i bed i n st ep I I I - 10.
81. Face mi l l and r eamt he t op of t he
head t ube wi t h a Campagnol o #733
t ool or equi val ent . ( See
Sut her l and' s Manual f or t he
pr oper use of cut t i ng t ool s. )
( See Fi g. 78)
82. Face mi l l and r eamt he bot t omof
t he head t ube as i n st ep 111- 81.
I V. THE FORK - Al l mat er i al s needed f or
t he const r uct i on of t he f or k have
al r eady been l i st ed.
1. Cl ean and pr ep t he f or k bl ade
t i ps and dr opout s f or si l ver
br azi ng.
2. Appl y flux.
3. Set bot h f or k bl ades upr i ght i n
t he vi se wi t h t he dr opout s i n
3- 26
CO. I N. pl ace. ( Make sur e t he cor r ect
bl ades ar e wi t h t he cor r ect
dr opout s. ) Gent l y t i ght en down
t he sof t j aws of t he vi se j ust
enough t o hol d t he f or k bl ades
f or si l ver br azi ng. ( See Fi g.
96)
4. Whi l e doi ng t he pr eheat ,
concent r at e appr oxi mat el y 60 t o
70 per cent of t he heat on t he
dr opout s. Thi s i s because t he
dr opout s ar e consi der abl y t hi cker
t hant he bl ades. They wi l l
r equi r e mor e heat dur i ng t he
pr eheat . ( See Fi g. 96)
5. I f t he bl ades have domed ends,
si l ver br azi ng wi l l be ver y easy.
J ust add t he si l ver behi nd t he
eyel et and dr aw i t ar ound. Then
add i t t o t he t op por t i on of t he
dr opout and dr aw i t ar ound t he
ot her way. I f l ar ge scal l ops
wer e cut out i n st ep I I
.
- 7 of
t he gener al pr ep, t her e wi l l be
l ar ge cr escent shaped hol es t o
f i l l . Thi s i s a di f f i cul t t r i ck
t o do wi t h si l ver . To do t hi s
t he met al must be kept ver y cl ose
t o t he mel t i ng t emper at ur e of t he
si l ver . Begi nni ng f r amebui l der s
may opt f or br ass t o at t ach
scal l oped dr opout s. However , use
of br ass i s not hi ghl y
r ecommended. ( See Fi g. 96)
6. Af t er t he j oi nt s have cool ed
suf f i ci ent l y, cl ean t he ar ea wi t h
hot wat er and aci d. Ri nse
t hor oughl y and bl ow dr y wi t h t he
compr essor .
7. Ther e wi l l mor e t han l i kel y be
excessi ve dr opout mat er i al t o be
f i l ed away t o have a smoot hl y
f i ni shed j oi nt . Whi l e f i l i ng be
car ef ul not t o cut i nt o t he f or k
bl ade. Thi s wi l l cause unsi ght l y
under cut t i ng. Be car ef ul t o f i l e
away onl y dr opout mat er i al .
Fi nal f i l i ng shoul d be done wi t h
a hal f r ound j ewel er ' s f i l e. The
j oi nt shoul d t hen be sanded wi t h
a 120 gr i t emer y cl ot h st r i p.
Set asi de t he bl ades.
3- 27
CO. I N.
8. I nser t t he t hr eaded por t i on of
t he st eer i ng col umn i nt o t he
l ar ger sl eeve of t he dummy
headset . The t op of t he st eer i ng
col umn shoul d be f l ush wi t h t he
t op of t he dummy headset .
Ti ght en t he set scr ew.
9. I nser t t he but t ed end of t he
st eer i ng col umn i nt o t he head
t ube. Sl i de t he smal l er sl eeve
of t he dummy headset ont o t he
bot t omof t he st eer i ng col umn.
Now sl i de t he f or k cr own i nt o
pl ace. ( See Fi g. 80)
10. I f l ess t han 2cmpr ot r udes beyond
t he bot t omof t he f or k cr own,
scr i be t he st eer i ng col umn f or a
r ough cut and cut of t he unneeded
por t i on of f t he col umn. ( See
Fi g. 80 & 81)
11. I f 2 t o 6cmpr ot r udes beyond t he
bot t omof t he f or k cr own, cut
hal f of t he excess of f of t he t op
t hr eaded par t of t he col umn.
Then r emeasur e and cut t he r est
of t he excess of f of t he bot t om
of t he st eer i ng col umn. ( See
Fi g. 80 & 81)
12. I f mor e t han 6cmof excess
st eer i ng col umn pr ot r udes beyond
t he bot t omof t he f or k cr own, one
of t wo t hi ngs can be done:
1 - A shor t er st eer i ng col umn can
be or der ed f r omt he suppl i er .
2 - Don' t cut anyt hi ng of f of t he
bot t omof t he col umn and add 5cm
of t hr eads t o t he t op of t he
col umn so t hat t he excess can be
cut of f t he t op l at er . ( I f t her e
i s over 6cmof excess, t he f i r st
opt i on shoul d be used. ) ( See
Fi g. 80 & 81)
13. Cl ean and pr ep t he f or k cr own and
st eer i ng col umn f or si l ver
br azi ng. ( See Fi g. 82)
14. Appl y f l ux. ( See Fi g. 83 & 84)
15. The t hr eaded end of t he col umn
can be hel d i n t he sof t j aws of
t he vi se so t hat t he col umn i s i n
3- 28
CO. I N. a hor i zont al pl ane. No ot her
j i ggi ng i s necessar y f or t hi s
j oi nt . ( See Fi gs. 83, 84, 85 &
86)
16. Bot h par t s bei ng si l ver br azed at
t hi s t i me ar e equal l y massi ve and
bot h ar e r at her t hi ck. I t i s
r eal l y di f f i cul t t o r ui n t hi s
j oi nt . Add t he si l ver ont o t he
smal l amount of excess pr ot r udi ng
t hr ough t he bot t omof t he cr own
and dr aw i t up t i l l i t appear s
ar ound t he f or k cr own r ace seat .
Be mor e f or cef ul wi t h t he f l ame
t o dr aw t he si l ver ont o t he si des
of t he j oi nt . The f l ame can al so
be ai med up i nsi de t he bot t omof
t he st eer i ng col umn t o dr aw t he
si l ver ar ound t he si des. The
br ake bol t hol e i s a good spot t o
wat cht oseei f adequat e
penet r at i on i s bei ng
accompl i shed. ( See Fi g. 85)
17. Al l ow t he j oi nt t o cool
suf f i ci ent l y bef or e cl eani ng up
wi t h hot wat er and aci d. Do not
hol d your hand over t he t op of
t he st eer i ng col umn whi l e dunki ng
i t i n t he wat er . I f t he j oi nt i s
st i l l qui t e hot , scal di ng hot
st eamwi l l shoot out of t he t op
of t he st eer i ng col umn l i ke a
smoke st ack.
18. Fi l e down any excess st eer i ng
col umn pr ot r udi ng t hr ough t he -
f or k cr own. Fi nal f i l i ng shoul d
be done wi t h a j ewel er
'
s f i l e.
Sandi ng shoul d be done wi t h a 120
gr i t emer y cl ot h st r i p. ( See
Fi gs. 87 & 88)
19. I f t he st eer i ng col umn st i l l has
t o be cut t o l engt h, do so at
t hi s t i me. The dummy headset can
be i nst al l ed t o f i nd t he pr oper
l engt h. ( I f a dummy headset i s
not avai l abl e, t he st eer i ng
col umn f r om t he t op of t he
t hr eaded por t i on t o t he base of
t he cr own r ace seat shoul d
measur e 40mml onger t han t he head
t ube. ) Af t er cut t i ng t he
st eer i ng col umn t o l engt h,
3- 29
CO. I N. car ef ul l y f i l e a smal l bevel
ar ound t he t op t o be sur e t he
f i r st t hr eads ar e cl ear ed so a
headset nut wi l l scr ew on.
20. Fi l e a f l at on t he back si de of
t he t op of t he st eer i ng col umn.
( Thi s wi l l be t he back si de of
t he f or k when i t i s f i ni shed. )
Be car ef ul not t o f i l e t hr ough
t he wal l of t he st eer i ng col umn.
The f l at shoul d ext end 1cmdown
f r omt he t op of t he st eer i ng
col umn. A keyed headset washer
can be used t o check f or f i t
whi l e t he f i l i ng i s bei ng done.
( See Fi g. 94 & 95)
21. Dr i l l out t he br ake hol e t o 1/ 4".
Unl ess t hi s st ep i s bei ng done on
a mi l l , t he br ake hol e shoul d be
dr i l l ed t hr ough one si de and t hen
t hr ough f r omt he ot her si de.
Thi s wi l l assur e t hat t he br ake
hol e goes t hr ough depr essi ons,
di mpl es or pr e- dr i l l ed hol es i n
t he cr own. ( See Fi g. 89)
22. I f a count er bor ed hol e sui t abl e
f or f l ush mount al i en br ake bol t
nut i s desi r ed, t hi s i s t he t i me
t o do i t . Don' t f or get , t he
count er bor e wi l l be on t he back
si de of t he cr own. ( Thi s wi l l be
t he same si de t hat t he f l at on
t hest eer i ng col umn has been
f i l ed. ) Mount a 13/ 32"
count er bor e wi t h a 1/ 4" pi l ot i n
a dr i l l pr ess. ( I f a hand dr i l l
i s used f or t hi s pr ocedur e, t he
r i sk of br eaki ng of f t he 1/ 4"
pi l ot i s qui t e hi gh. )
Count er bor e t he 1/ 4
"
hol e i n t he
backsi de of t he cr own t o a dept h
of 2mm. Go easy on t he f eed as
t he count er bor e wi l l be an
ext r emel y shar p cut t i ng t ool and
wi l l go cl ear t hr ough t he cr own
i n shor t or der . ( Don' t f or get
t he cut t i ng oi l ! ) Af t er t he
count er bor i ng i s f i ni shed, t he
r emai ni ng 1/ 4" hol e i n t he back
of t he cr own must be dr i l l ed out
t o 21/ 64" ( See Fi g. 90)
3- 30
CO. I N.
23. The f or k cr own r ace seat must be
mi l l ed next . Cl amp t he cr own i n
t he sof t j aws of t he vi se so t hat
t he st eer i ng col umn i s i n a
ver t i cal posi t i on. Mi l l wi t h
Campagnol o t ool #718 or
equi val ent . ( See Sut her l and' s
Manual f or t he pr oper use of
cut t i ng t ool s. ) ( See Fi gs. 91,
92 & 93)
24. Check now t o see i f t he f or k
bl ades wi l l f i t easi l y i nt o t he
cr own. The f i t wi l l usual l y be
t i ght . Her e agai n a . 004"
cl ear ance i s r equi r ed f or si l ver
br azi ng. I f t he f i t i s t i ght ,
t he f i r st t hi ng t hat must usual l y
be done i s t o f l at t en t he oval
cr oss sect i on of t he bl ades i n
t he sof t j aws of t he vi se by
near l y a mi l l i met er . I f t hi s
doesn' t do t he t r i ck, t hen do as
f ol l ows:
1 - I f usi ng an over l appi ng
cr own, car ef ul l y enl ar ge t he
oval hol e i n t he cr own wi t h a
3/ 8" di amet er cyl i ndr i cal
st one mount ed i n t he chuck of
a di e gr i nder . DO NOT TAKE
MATERI AL OFF THE OUTSI DE OF
THE FORK BLADES! !
2 - I f usi ng an i nser t ed cr own,
f i l e down t he out er sur f ace
of t he i nser t i ons on t he
bot t omof t he cr own. DO NOT
REAMTHE I NSI DE OF THE FORK
BLADES! ! ( See Fi gs. 99, 100
& 101)
25. The f or k bl ades must now be cut
t o l engt h. Assembl e t he f or k.
( I t wi l l be about 5cmt oo l ong at
t hi s poi nt . ) Mount t he dummy
br ake i n t he br ake hol e. Put t he
wheel t hat wi l l be used i n t he
dr opout s but do not cl amp t he
qui ck r el ease. Measur e t he
di st ance f r omt he mar k on t he
dummy br ake ( Ther e wi l l be one
mar k f or shor t r each br akes and
anot her mar k f or r egul ar r each
br akes. ) down t o t he cent er of
t he r i mwher e t he br ake shoes
shoul d hi t . Thi s i s t he amount
3- 31
CO. I N. t hat needs t o be cut of f t he
bl ades. ( See Fi gs. 102, 103, &
104)
26. Cut one mi l l i met er l ess t han t he
necessar y amount of f t he f or k
bl ades. ( Af t er f i l i ng and f i nal
f i t t i ng t hat mi l l i met er wi l l
easi l y be l ost . ) ( See Fi g. 104)
27. Cl ean t he bur r out of t he t op of
t he bl ades.
28. Assembl e t he f or k agai n. Put i n
t he wheel agai n. Do not t i ght en
t he qui ck r el ease. Look t o see
i f t he wheel si t s cl oser t o one
bl ade. I f t he wheel si t s cl oser
t o one bl ade, t hat bl ade i s
l onger . I t must be f i l ed
shor t er . When bot h bl ades appear
t o be equi di st ant f r omt he wheel ,
t her e i s anot her f i nal check t o
be made. Look down t hr ough t he
st eer i ng col umn t o see i f t he
wheel i s cent er ed f r omt hat vi ew
al so. I f t he wheel i s cent er ed,
go on t o t he next st ep.
NOTE - Ti ght eni ng t he qui ck
r el ease dur i ng t hi s pr ocedur e
wi l l t hr ow of f al i gnment due
t o t wi st or cast er i n t he
dr opout s whi ch i s mor e t han
l i kel y pr esent at t hi s t i me.
NOTE - The wheel used dur i ng
t hi s pr ocedur e shoul d be i n
excel l ent t r ue and di shed
per f ect l y. Many bui l der s
keep a speci al set of wheel s
on hand f or t hi s pur pose.
NOTE - When f i ni shed wi t h
t hi s st ep, t he f or k must
near l y f al l t oget her . Ther e
can be no f or ce f i t s i n t he
f or k. For ce f i t s wi l l cause
pr obl ems dur i ng and af t er
br azi ng.
NOTE - Ther e can be no gaps
bet ween t he t ops of t he
bl ades and t he bot t omof t he
f or k cr own. These gaps wi l l
3- 32
CO. I N. act ual l y cl ose t hemsel ves up
dur i ng t he si l ver br azi ng
pr ocess and t hr ow of f
al i gnment el sewher e. ( See
Fi g. 105, 106 & 107)
29. Any t wi st or cast er must be
r emoved f r omt he dr opout s at t hi s
t i me. Assembl et he f or k and
f r ont wheel agai n. See i f t he
dr opout s l i e f l at agai nst t he
l ocknut s. I f t hey don
'
t , bend
t he dr opout s so t hey do l i e f l at .
( See Fi gs. 108 & 109)
30. Dr i l l t wo ai r expansi on hol es
i nt o t he i nsi de f aces of each
bl ade. One hol e shoul d be about
15mmf r omt he t op of t he bl ade.
The ot her shoul d be about 15mm
f r omt he bot t om. 5/ 64" i s a good
si ze t o use f or t hese ai r
expansi on hol es. Havi ng t wo
hol es i n each bl ade makes t he
f i nal met al pr ep much easi er . DO
NOT DRI LL THE HOLES I N THE SAME
SI DE THAT THE NAME I S STAMPED I N
THE DROPOUTS! Some f or k cr owns
make pr ovi si ons f or hi dden ai r
expansi on hol es. I n t hat case a
set of hol es near t he dr opout s
need t o be dr i l l ed. The second
set must be dr i l l ed at t he t op of
t he i nsi de f aces of t he bl ades
and 1/ 4
"
i n di amet er . ( See Fi g.
97)
31. Cl ean and pr ep t he cr own and t ops
of t he bl ades f or si l ver br azi ng.
32. Appl y f l ux.
33. Set t he f or k j i g f or t he cor r ect
amount of r ake. Make sur e t hat
bot h dr opout s wi l l be si t t i ng at
t he same r ake. I f one si de i s
hi gher t han t he ot her , t her e wi l l
be t wi st i n t he f or k. ( See Fi g.
110)
34. Put t he f or k i nt o t he j i g and
moder at el y t i ght en down t he cl amp
on t he st eer i ng col umn.
3- 33
35. Before clamping down on the
dropouts, tap themwith a brass
hammer to be sure they are seated
in place. Clamp themdown. (See
Fig. 112)
36. Before clamping the steering
column fully, tap the top of it
to be sure the blades bottomout
in the crown.(See Fig. 111)
37. Set the fork twist indicator down
across the tops of blades and
take a reading. Flip-flop the
indicator and take another
reading. Both readings should be
the same. If not, twist the
crown as necessary and take the
readings again. This will
probably have to be done several
times before arriving at a good
set of readings. (Twisting the
crown can be done quite easily by
inserting a 1/4" diameter rod
through the brake hole and using
it as a lever.) When the two
readings are the same, tighten
down the steering column clamp.
Take the readings again to make
sure twisting did not occur
during tightening. (See Figs.
113, 114& 115)
38. If tangs are being used with the
crown, they should be clamped
against the blades with the
modified C-Clamp #1.
39. The fork is now ready for silver
brazing. Due to the mass of the
crown, this is a long preheat so
take the phone off the hook
before starting. (See Figs. 116
& 117)
40. Allow the fork to cool thoroughly
before cleaning it up with hot
water and acid. Immersing a hot
fork in water can have a serious
effect on alignment.
41. If an inserted crown has been
used, it must now be filed to be
flush with the surface of the
blades. Final filing should be
3-34
CO. I N. done wi t h a j ewel er ' s f i l e and
f i nal sandi ng shoul d be done wi t h
a 120 gr i t emer y cl ot h st r i p.
By t hi s t i me you ar e pr obabl y
f ed up wi t h t he j ewel er ' s
f i l e and sandpaper r out i ne.
However , i t i s necessar y.
Any f i l e mar ks t hat ar e
pr esent can devel op i nt o
st r ess cr acks. The smal l er
t he f i l e mar ks or sandi ng
mar ks t he l ess t her e i s a
chance of st r ess cr acks
devel opi ng.
42. For k al i gnment shoul d be checked
i n t he par k f or k al i gnment j i g
and t i ps shoul d be al i gned wi t h
f i gur e "I i " t ool s. ( See Fi g. 118)
V. THE REAR TRI ANGLE
1. Sl i de t he shor t er por t i on of t he
dummy headset ont o t he st eer i ng
col umn. Sl i de t he st eer i ng
col umn up t hr ough t he head t ube
and t hen put t he t al l er por t i on
on t het op of t he st eer i ng
col umn. Ti ght en down t he
t humbscr ew on t he dummy headset
t o a snug f i t . The par t i al l y
f i ni shed f r ameset i s r eady t o put
i nt o t he r ear end j i g. ( See Fi g.
119)
2. Mount t he r ear end j i g ( See
Fi xt ur es. ) i n t he vi se and l evel
i t usi ng t he l ong base as a
r ef er ence. I f usi ng a Par k
st and,
"
Donut s" can be or der ed
f r omPar k Tool so t hat t he r ear
end j i g can be f ast ened t o and
mount ed i n t he Par k st and.
3. Fast en t he seat t ube i nt o t he
seat t ube cl amp of t he j i g but do
not t i ght en al l t he way yet .
4. Rest t he dr opout s of t he f or k on
t he T- bar on t he f r ont of t he
j i g.
5. Wi t h a 12" st eel r ul e, scr ape t he
si des of t he f or war d por t i on of
3- 35
CO. I N. t he down t ube and t he f or war d
por t i on of t he t op t ube at t he
same t i me. Thi s wi l l et ch
cent er l i nes on t he si des of t he
t wo t ubes. ( See Fi g. 120)
6. Wi t h t he 12" st eel r ul e, scr ape
t he si des of t he r ear por t i on of
t he t op t ube and t he t op por t i on
of t he seat t ube at t he same
t i me. Thi s wi l l et ch cent er l i nes
al ong t he si des of t hese t wo
t ubes. ( Fi g. 121)
7. Usi ng t he r ef er ence sur f ace f r om
t he l evel i ng pr ocedur e, measur e
st r ai ght up t o t he cent er l i ne
et ched at t he f or war d por t i on of
t he t op t ube. Make not e of t hat
measur ement . ( See Fi g. 123)
8. Usi ng t he same r ef er ence sur f ace,
measur e st r ai ght up t o t he l i ne
et ched on t he r ear por t i on of t he
t op t ube. Make not e of t hat
measur ement . ( See Fi g. 122)
9. Compar e t he t wo measur ement s j ust
t aken. I f one i s hi gher t han t he
ot her , l oosen t he seat t ube cl amp
assembl y and r ai se or l ower i t as
necessar y t o l evel t he t op t ube.
Af t er t hi s st ep i s compl et ed t he
t op t ube and t he l ong base of t he
j i g shoul d be par al l el wi t h each
ot her .
10. Check t o see t hat t he angl e bar
i s t ouchi ng bot h seat t ube and
down t ube. Check t o see i f t he
bot t ombr acket shel l i s r est i ng
on t he peg i n t he seat t ube cl amp
assembl y. I f t hese i t ems ar e i n
or der , t i ght en t he seat t ube
cl amp.
I f t he or i gi nal dr awi ng was
made wi t h a hor i zont al t op
t ube, al l owances wer e made
f or a dummy headset & t he
f or k has been bui l t as
speci f i ed i n t he dr awi ng
t hen, at t hi s poi nt , t he head
t ube angl e, seat t ube angl e
3- 36
CO. I N. and bot t ombr acket dr op wi l l
aut omat i cal l y f i nd t hem-
sel ves. Success i n achi evi ng
t hi s i s gr eat l y dependent on
how cl ose t o t he dr awi ng t he
f r ont t r i angl e cor r esponds.
At t hi s t i me seat t ube, head
t ube, and t op t ube angl es can
be checked agai nst t he
dr awi ng. Bot t ombr acket dr op
can al so be checked now.
( See Fi gs. 124, 125, 126,
127, & 128)
11. Cl ean and pr ep t he ends of t he
chai nst ays and r ear dr opout s f or
si l ver br azi ng.
12. Appl y f l ux.
13. Si l ver br aze t he dr opout s i nt o
t he chai nst ays.
14. Af t er t he pi eces have cool ed
suf f i ci ent l y, cl ean t hemup wi t h
hot wat er and HC1 aci d.
15. Excess dr opout mat er i al wi l l be
pr ot r udi ng beyond t he sl ot i n t he
chai nst ays. Thi s must be f i l ed
down t o be f l ush wi t h t he
chai nst ays. Rough i n car ef ul l y
wi t h t he gr i nder . Cl ean up wi t h
an 8
"
hal f r ound f i l e. ( Be ver y
car ef ul not t o t ake mat er i al away
f r omt he chai nst ays, t he onl y
mat er i al t hat shoul d be f i l ed
away i s t he act ual dr opout . )
Fi ni sh t he cl ean up wi t h a hal f
r ound j ewel er
'
s f i l e and 120 gr i t
emer y cl ot h.
16. Set t he sl i di ng r ear axl e post of
t he r ear end j i g f or t he cor r ect
chai nst ay l engt h. ( See Fi g. 129)
17. Rough cut t he chai nst ays one
cent i met er l onger t han necessar y
and f i l e t he bur r of f t he end.
( See Fi g. 130 & 131)
18. I f t he chai nst ays wi l l not easi l y
sl i de i nt o cor r espondi ng hol es of
t he bot t ombr acket shel l and
easi l y dr op i nt o pl ace on t he
3- 37
CO. I N. sl i di ng r ear axl e post , t hen
t hose hol es must be r eamed. ( See
Fi g. 132)
19. To r eamt he hol es f or t he
chai nst ays, mount a 5/ 8" di amet er
cyl i ndr i cal st one i n a hi gh speed
di e gr i nder and r eamt i l l t he
chai nst ay/ dr opout assembl i es wi l l
sl i de i nt o pl ace. ( See Fi g. 132)
20. Cl ean up t he bur r ar ound t he
chai nst ay hol es i n t he bot t om
br acket wi t h a j ewel er ' s f i l e.
21. I nser t one chai nst ay i nt o pl ace
and scr i be wher e t he mi t er shoul d
be on t he i nsi de sur f ace of t he
bot t ombr acket shel l . ( Due t o
t he way t he j i g i s const r uct ed,
onl y one si de of t he chai nst ay
can be scr i bed. A l i t t l e guess
wor k wi l l be necessar y on t he
back si de. ) ( See Fi g. 133)
22. Do t hi s mi t er on t he gr i ndi ng
wheel . I t does not have t o be a
r eal l y neat mi t er as t he bot t om
br acket t aps wi l l event ual l y cut
st r ai ght acr oss i t .
23. Repeat st eps V- 21 & V- 22 f or t he
r emai ni ng chai nst ay.
24. Cl ean and pr ep t he ends of t he
chai nst ays and t he chai nst ay
hol es f or si l ver br azi ng. ( I t
woul d be wi se t o t i p t he j i g
upsi de down t o keep t he aci d f r om
get t i ng al l over t he j i g. )
25. Appl y f l ux. ( Thi s j oi nt i s r eady
but wi l l not be br azed f or at
l east an hour or mor e. )
26. Rai se t he seat st ay r est so t hat
when a seat st ay i s pushed on t o
t he r ear dr opout , t he t op of t he
seat st ay wi l l f al l al ong t he si de
of t he seat l ug. Ti ght en t he
r est i n t he cor r ect posi t i on.
3- 38
CO. I N.
27. Repeat st ep 11- 6 f r omt he gener al
pr epar at i on f or t he seat st ays
now. Af t er t he sl ot s i n t he
seat st ays mat ch t he t abs on t he
dr opout s, t her e shoul d be no gaps
bet ween t he t op of t he dr opout
t abs and t he bot t omof t he
seat st ay sl ot s when t he seat st ay
i s put i nt o pl ace. ( See Fi g.
134)
28. Fi l e a f l at on t he i nsi de f ace of
t he bot t omof t he r i ght seat st ay.
Thi s wi l l al l ow f or
spr ocket / chai n cl ear ance. ( See
Ar r ow, Fi g. 134)
29. Wr ap bands of maski ng t ape ar ound
each seat st ay. Mar k t he l ef t one
wi t h an L and t he r i ght one wi t h
an R. Put t hese l et t er s on t he
out si de sur f aces of bot h st ays.
Thi s wi l l l essen t he chance of
r ot at i ng t he st ays whi l e doi ng
f ut ur eoper at i ons. ( Don' t
f or get , t he sl ot s i n t he
seat st ays had t o be f i l ed at an
angl e and r ot at i on of t he st ay
can cause pr obl ems up at t he seat
cl ust er .
30. Choose t he st yl e of seat cl ust er
t hat wi l l be used f r omt he
var i at i ons sect i on of t hi s
manual . ( Begi nni ng bui l der s
shoul d t r y st ar t i ng out wi t h t he
use of sl ugs. ) ( See Fi g. 135)
31. I f t he sl ugs wi l l not i nser t , i nt o
t he seat st ays wi t h a pr oper
si l ver br aze f i t , f i l e down t hei r
di amet er so t hat t hey wi l l f i t
easi l y.
32. Put t he seat st ays i nt o pl ace wi t h
t he sl ugs i nser t ed. Si nce t he
seat st ays have not been cut t o
l engt h yet , t hey wi l l be at l east
6 t o 8cmt oo l ong now.
3- 39
CO . I N.
33. Measur e how much t oo l ong t he
seat st ay/ sl ug assembl i es ar e.
Remove t he sl ugs and cut t hi s
amount of f t he seat st ays. ( I f
i n doubt , cut of f 2mml ess t han
what ' s cal l ed f or . )
34. Some f i nal f i l i ng may be
necessar y t o br i ng t he t wo
seat st ay/ sl ug assembl i es t o t he
r i ght l engt h.
35. Squar e up t he t ops of t he
seat st ays wi t h an 8
"
f l at f i l e.
36. Remove t he bur r f r omt he i nsi de
of t he t ops of t he seat st ays. Do
not r emove t he bur r f r omt he
out si des of t he seat st ays.
37. Cl ean and pr ep t he t ops of t he
seat st ays and t he sl ugs f or
si l ver br azi ng.
38. Appl y f l ux.
39. Rei nst al l t he seat st ay/ sl ugs.
The sl ugs shoul d be si l ver br azed
i nt o t he seat st ays whi l e
ever yt hi ng i s i n pl ace. Thi s way
an unsi ght l y r ot at i on of t he sl ug
can be det ect ed bef or e br azi ng i s
done. When t her e i s no
det ect abl e r ot at i on i n t he sl ugs,
br aze t hemi n pl ace. Use a
l i t t l e ext r a amount of si l ver f or
t hi s j oi nt so t hat any seamwi l l
be t ot al l y cover ed up.
I MPORTANT - - You ar e not
br azi ng t he sl ugs t o t he
si des of t he seat l ug at t hi s
t i me!
40. Af t er t he j oi nt s have cool ed
suf f i ci ent l y, cl ean t hem wi t h
wat er and aci d.
41. Fi l e t he seams t hat ar e l ef t
bet ween t he sl ug and t he
seat st ays. Do t hi s wi t h a f i ne
t oot hed 8" f l at f i l e. A def i ni t e
3- 40
CO. I N. t echni que must be mast er ed f or
doi ng t hi s t ype of f i l i ng on a
cur ved sur f ace. As t he f i l e goes
ar ound t he t ube, t he bui l der ' s
hands shoul d f ol l ow i n an ar c-
l i ke mot i on. I f done pr oper l y,
t her e wi l l be a mi ni mumof f acet s
i n t he f i l i ng wor k.
42. Remove any f i l e mar ks wi t h an 80
gr i t emer y cl ot h st r i p. Fi ni sh
up wi t h 120 gr i t .
43. Dr i l l 5/ 64" ai r expansi on hol es
i n bot h ends of each seat st ay.
The hol es shoul d be on t he i nsi de
f aces so t hey ar e out of vi ew.
Dr i l l one hol e at t he seamof t he
sl ug. Dr i l l t he ot her hol e 2cm
up f r omt he sl ot . Repeat f or t he
ot her st ay.
44. Cl ean and pr ep bot h ends of bot h
st ays f or si l ver br azi ng.
45. Cl ean and pr ep t he seat l ug f or
si l ver br azi ng. ( Do t hi s wi t h
t he j i g upsi de down so as not t o
get aci d on t he j i g. I t i s no
l onger necessar y t o keep t he j i g
l evel . )
46. Whi l e t he j i g i s st i l l upsi de
down, cl ean and pr ep t he t abs on
t he dr opout s f or si l ver br azi ng.
47. Appl y f l ux.
48. St ar t i ng at t he bot t ombr acket ,
t ack t he chai nst ays i nt o t he
bot t ombr acket shel l . ( J ust t ack
t hem. The j oi nt wi l l be f i ni shed
up l at er . ) ( See Fi g. 136)
49. Si l ver br aze t he seat st ays i nt o
t he dr opout s. ( See Fi g. 137)
50. Si l ver br aze t he sl ugs t o t he
si des of t he seat l ug. ( Thi s may
r equi r e some f i l l et bui l di ng wi t h
t he si l ver . ) ( See Fi g. 138)
51. Remove t he f r ame f r omt he r ear
end j i g.
3- 41
CO. I N.
52. Fi ni sh t he br azi ng of t he
chai nst ays i nt o t he bot t om
br acket shel l . ( See Fi g. 139)
53. Fi l e t he excess dr opout mat er i al
f r omwher e i t pr ot r udes beyond
t he sur f ace at t he bot t omof t he
seat st ays. ( Thi s i s a r epeat of
st ep V- 15. )
54. The seat t ube shoul d be r eamed
wi t h a Chadwi ck #28 adj ust abl e
r eamer t o at t ai n an easy sl i de
f i t wi t h t he seat post . Fol l ow
t hi s by honi ng l i ght l y wi t h a
br ake cyl i nder hone. ( See Fi g.
140)
55. Dr i l l a 7/ 32
"
st r ess r el i ef hol e
wher e t he bot t omof t he bi nder
sl ot wi l l f al l . ( See Fi g. 142)
56. Cut t he bi nder sl ot . Thi s sl ot
shoul d be 1 t o 2mmwi de. To
achi eve t hi s wi dt h, ei t her
sandwi ch 2 bl ades i n a hacksaw or
use an abr asi ve cut of f wheel .
( See Fi g. 143)
VI . BRI DGES AND BRAZE- ONS
1. Af t er t he r ear t r i angl e was
assembl ed and br azed i n pl ace,
t he dr opout s mor e t han l i kel y
pul l ed t oget her so t hat a
st andar d r ear hub cannot be put
i n pl ace wi t hout f or ci ng i t i nt o
t he dr opout s. That bei ng t he
case, t he r ear end must be spr ead
open t o t he r i ght wi dt h. To do
t hi s, you must be cer t ai n t hat
t he r ear t r i angl e and f r ont
t r i angl e ar e i n t he same pl ane.
I f t hey ar e not i n t he same
pl ane, t hey shoul d be af t er t hi s
col d set t i ng pr ocedur e. Measur e
t he di st ance bet ween t he i nsi de
f aces of t he r ear dr opout s. The
di st ance shoul d be 120mmf or a
f i ve speed r ear end and 125mmf or
a si x speed r ear end. Take not e
of how much t he r ear end has t o
be spr ead. ( The r ear end usual l y
pul l s i n 2 t o 4mmdur i ng t he
3- 42
CO. I N. si l ver br azi ng pr ocess. ) ( See
Fi g. 141)
2. Use t he Par k FAG- 1 t ool or a
st r i ng wi t h r ubber bands at each
end t o check i f bot h t r i angl es
ar e i n t he same pl ane. Use t he
Par k t ool as per t he di r ect i ons.
I f t he st r i ng met hod i s used,
at t ach one end of an eyel et i n
t he r ear dr opout , r un i t up
ar ound t he head t ube and at t ach
t he ot her end t o t he ot her
dr opout eyel et . Now measur e t he
di st ance bet ween t he st r i ng and
t he seat t ube on bot h si des and
col d set as f ol l ows: ( See Fi g.
141)
A. I f t he wi dt h measur ement i s
OK bet ween t he dr opout s but
t he r ear t r i angl e i s out of
pl ane wi t h t he f r ont
t r i angl e, put a r ear hub or
axl e set i n t he r ear dr opout s
and bend bot h si des at once
wi t ht her ear t r i angl e
per suader ( See Fi xt ur es)
unt i l bot h t r i angl es ar e t he
same pl ane.
B. I f t he wi dt h measur ement i s
t oo cl ose bet ween t he
dr opout s and t he r ear
t r i angl e i s out of pl ane wi t h
t he f r ont t r i angl e, pul l
out war d on t he cor r ect
dr opout t o br i ng t he t r i angl e
i nt o pl ane and get t he
cor r ect wi dt h at t he same
t i me.
C. I f t he wi dt h measur ement
bet ween t he dr opout s i s t oo
cl ose but t he t r i angl es ar e
bot h i n t he same pl ane, pul l
on bot h dr opout s t o get t he
cor r ect wi dt h and st i l l st ay
i n pl ane.
I f t he r ear t r i angl e per suader i s
not avai l abl e f or pr obl emA,
cl amp t he bot t ombr acket f aces i n
t he sof t j aws of t he vi se and
3- 43
pul l on each dr opout at a t i me.
Pul l t hemi n t he same di r ect i on.
3. Put t he f r ame, dummy headset and
f or k t oget her . Put a set of
f r amebui l der ' s wheel s i n t he
dr opout s. ( I f al so desi r ed, put
i n a seat post , saddl e, bar s and
st em. ) The f r ameset shoul d now
be scr ut i ni zed t o see how wel l i t
wi l l t r ack and how wel l t he
wheel s set i n t he dr opout s. The
most cr i t i cal i t emt o be l ooki ng
f or at t hi s t i me i s t o see i f t he
r ear wheel comes cl oser t o one
chai nst ay t han t he ot her or i f i t
comes cl oser t o one seat st ay t han
t he ot her . I f t her e i s a
pr obl em, do as f ol l ows:
A. I f t he wheel si t s cl oser t o
t he r i ght chai nst ay, heat up
t he j oi nt wher e t he l ef t
chai nst ay j oi ns t he dr opout
and pul l t he j oi nt apar t
sl i ght l y unt i l - t he desi r ed
al i gnment i sachi eved.
( Vi ce- ver sa f or t he ot her
si de) Cosmet i c wor k wi l l be
necessar y af t er t hi s
pr ocedur e. I f dr opout s wi t h
chai n adj ust er s have been
used, t he adj ust er s wi l l
pr obabl y be abl e t o t ake up
any di f f er ence. I n t hat case
i t i s not necessar y t o pul l
t he j oi nt apar t .
B. I f t he wheel si t s cl oser t o
t he r i ght seat st ay, heat up
t he j oi nt wher e t he l ef t
seat st ay j oi ns t he dr opout
and pul l t he j oi nt apar t
sl i ght l y unt i l t he desi r ed
al i gnment i s achi eved.
( Vi ce- ver sa f or t he ot her
si de) Cosmet i c wor k wi l l
pr obabl y be necessar y af t er
t hi s pr ocedur e. Thi s t ype of
al i gni ng may be necessar y
r egar dl ess of whet her
st andar d r oad dr opout s or
ver t i cal dr opout s have been
used.
3- 44
CO. I N. I T I S UNACCEPTABLE TO ALTER THE
SLOT I N THE DROPOUT TO ACHI EVE
CORRECT ALI GNMENT. ANYONE WHO
FI LES THE DROPOUT SLOTS WI TH A
ROUND FI LE I S PRACTI CI NG
STONE- AGE STYLE FRAMEBUI LDI NG
TECHNI QUES! ! !
4. Di sassembl e t he bi ke down t o t he
bar e f r ame agai n.
5. Set t he dummy r ear wheel f or
cor r ect hub wi dt h. ( 125mmf or 6
speed and 120mmf or 5 speed)
( See Fi g. 145)
6. Set t he dummy wheel f or t he
cor r ect t i r e r adi us. ( 33. 7cmf or
700c and 34cmf or 27") ( See Fi g.
145)
7. Put t he dummy r ear wheel i n pl ace
bet ween t he dr opout s wi t h t he
poi nt bet ween t he seat st ays.
( See Fi g. 145)
8. Ther e shoul d be mar ks on t he
dummy wheel wher e t he br ake shoes
shoul d hi t si des of a 700c wheel
and/ or a 27
"
wheel . Choose t he
cor r ect mar k t o wor k wi t h.
9. Deci de i f shor t r each or r egul ar
r each br akes wi l l be used. The
br ake br i dge hol e cent er wi l l be
47mmabove t he chosen mar k on t he
dummy wheel f or shor t r each
br akes. ( 52mmf or r egul ar r each
br akes)
10. Mi t er t he br ake br i dge t o f i t
bet ween t he st ays at t he cor r ect
di st ance f r omt he mar k on t he
dummy wheel t hat was chosen.
Thi s i s met i cul ous mi t er i ng wor k.
The mi t er s on each end of t he
br i dge must be i n t he same pl ane.
The angl es f i l ed on t he ends of
t he br i dge must mat ch t he sl i ght
angl e of t heseat st ays. I f
t her e i s any gap what soever
bet ween t he br i dge and seat st ays,
t he dr opout s wi l l pul l t oget her
agai n. The br i dge must be a ver y
snug f i t as i t i s pushed up i nt o
3- 45
CO. I N. pl ace or , agai n, t he dr opout s
wi l l pul l t oget her dur i ng si l ver
br azi ng.
11. I f a st andar d br i dge i s bei ng
used, an ai r expansi on hol e must
be dr i l l ed. To have t he hol e
t ot al l y hi dden, dr i l l one hol e i n
each seat st ay wher e t he br i dge
wi l l be br azed i nt o pl ace. When
t he br i dge i s pushed up i nt o
pl ace, t he hol es wi l l be cover ed
up. I f anot her st yl e of br i dge
i s bei ng used, see t he sect i on on
br ake br i dge var i at i ons f or
r ecommendat i ons on ai r expansi on
hol es.
12. I f a st andar d br ake br i dge i s
bei ng used, do not dr i l l t he
br ake hol e yet . I f a st andar d
br ake br i dge wi t h a cyl i ndr i cal
boss or any of t he Ci nel l i
br i dges ar e bei ng used, br i dge
pi eces must be pr eassembl ed,
al i gned, and si l ver br azed bef or e
t he br i dge i s br azedt o t he
st ays. ( See Fi g. 146)
13. I f di amond st i f f ener s ar e t o be
used, go back t o st ep 10 and
mi t er t he br i dge shor t er on bot h
si des t o al l ow f or t he t hi ckness
of t he st i f f ener s.
14. Bef or e si l ver br azi ng, assembl e
t he br i dge par t s and sl i de t hem
i nt o pl ace. Check t o see i f t he
br ake hol e ( i f pr edr i l l ed) si t s
i n t he exact cent er , see i f t he
br i dge i s cocked i n any pl ane,
and see t hat t he br i dge i s not
r ot at ed f or war d or backwar d. I f
ever yt hi ng checks out , go t o t he
next st ep. I f not , make
al t er at i ons or make a new br i dge.
( Do not t hr ow a bad br i dge away.
I t coul d be used on a smal l er
f r ame at a l at er dat e. )
15. Cl ean and pr ep al l of t he br i dge
par t s f or si l ver br azi ng.
16. Cl ean and pr ep t he seat st ays f or
si l ver br azi ng.
3- 46
CO. I N.
17. Appl y f l ux.
18. Assembl e br i dge par t s and sl i de
i nt o pl ace. I t may be necessar y
t o j i ggl e t he assembl y t o squeeze
excess f l ux out f r omunder t he
st i f f ener s.
19. Ti p t he f r ame upsi de- down bef or e
br azi ng t he br i dge i n. Thi s wi l l
keep i t f r omf al l i ng out when t he
f l ux becomes l i qui d. ( See Fi g.
147)
20. Af t er t he j oi nt s have cool ed
adequat el y, cl ean up wi t h hot
wat er and aci d and bl ow i t dr y.
21. Some cosmet i c cl ean up may be
necessar y.
22. I f usi ng a st andar d br i dge, dr i l l
t he br ake hol e at t hi s t i me.
Fi r st dr i l l a smal l pi l ot hol e.
Make sur e t he hol e i s cent er ed
al ong t he l engt h of t he br i dge.
Make sur e t he hol e goes t hr ough
per pendi cul ar t o t he pl ane t hat
t he seat st ays l i e i n. Havi ng a
hel per si ght i n f r omt he si de
hel ps i n dr i l l i ng a st r ai ght
hol e. Enl ar ge t he pi l ot hol e t o
t he necessar y si ze as f ol l ows:
A. I f no sl eeve wi l l be used,
dr i l l 1/ 4"
B. I f usi ng 5/ 16" x . 028
"
t ube
f or r ei nf or ci ng, dr i l l t he
hol e t o 5/ 16".
C. I f usi ng a f l anged
r ei nf or cement , dr i l l t he hol e
t o t he cor r ect si ze so t hat
t he r ei nf or cement wi l l sl i de
i n easi l y.
23. Dr i l l a 1/ 16" ai r expansi on hol e
t r ansver sel y t hr ough t he mi ddl e
of t he sl eeve.
24. Cl ean and pr ep t he br i dge and
sl eeve f or si l ver br azi ng.
25. Appl y f l ux.
3- 47
CO. I N.
26. Si l ver br aze t he sl eeve i nt o
pl ace.
27. Af t er t he br i dge has cool ed
adequat el y, cl ean up t he f l ux
wi t h hot wat er and aci d.
28. I f a si mpl e r ei nf or cement was
used, t he ends must be r ounded t o
be f l ush wi t h t he out si de
di amet er of t he br i dge.
29. I f a neat j ob was done, l i t t l e or
no cl ean up wi l l be necessar y on
f l anged r ei nf or cement s. Do not
f i l e t he excess of f t he backsi de
of t he f l anged r ei nf or cement .
Ther e shoul d be a f l at f or t he
washer and nut t o hi t agai nst
l at er .
30. Take out t he dummy wheel t o see
i f t he wi dt h bet ween t he dr opout s
i s sat i sf act or y. I f t hey have
pul l ed t oget her , r epeat st eps 1
and 2 of t hi s sect i on.
31. Put t he dummy wheel back i n.
Thi s t i me have t he poi nt bet ween
t he chai nst ays. ( See Fi g. 148)
32. Cut , f i t and mi t er t he chai nst ay
br i dge and si l ver br aze i t i n.
Ther e i s no need t o el abor at e
her e as al l t he st eps wi l l be t he
same as t hose f or t he br ake
br i dge. Some st eps wi l l be
el i mi nat ed f or obvi ous r easons.
33. At t hi s t i me r ear t r i angl e
al i gnment can be checked by t he
st r i ng met hod. I f t he st r i ng
t echni que i s used, t hr ee cr i t er i a
must be met .
1 - The seat and down t ubes as
t hey r adi at e f r omt he bot t om
br acket shel l must have no
l ef t or r i ght def l ect i on.
2 - The head t ube and seat t ube
must be i n t he same pl ane.
3 - Use a ver y f i ne st r i ng such
as monof i l ament f i shi ng l i ne.
Havi ng met t hese t hr ee cr i t er i a
3- 48
CO. I N. t he st r i ng met hod i s ext r emel y
accur at e. ( See Fi g. 141)
34. Check t he measur ement bet ween t he
dr opout s and dr opout al i gnment
wi t h t he Fi gur e
"
H
"
t ool s. Col d
set t i ng may be necessar y at t hi s
t i me. ( See Fi g. 149)
35. At t hi s t i me t he br aze- ons wi l l
be appl i ed. Br aze- on wor k t akes
l ot s of pr act i ce and a per sonal
t echni que must be devel oped.
( See Fi gs. 150, 151, 152, 153,
154, 155, 157, 158, 159)
NOTE: My f avor i t e way of
at t achi ng br aze- ons i s t o f l ux
bot h sur f aces, appl y a spot of
si l ver t o t he f r ame, hol d t he
br aze- on wi t h a cheap set of
needl e nose pl i er s, heat up t he
br aze- on, hol d t he br aze- on i n
pl ace and r eheat bot h t he spot of
si l ver and t he br aze- on. The
si l ver wi l l mel t and bond t he t wo
sur f aces t oget her . Smal l
f i xt ur es can be made f or some
br aze- ons.
36. A seamof si l ver shoul d be l ai d
ar ound t he di amet er s of t he seat
t ube, down t ube and chai nst ays
wher e t hey poke i nt o t he bot t om
br acket shel l . Thi s seam i s
bei ng appl i ed t o t he i nsi de
sur f ace of t he bot t ombr acket
shel l . Thi s seamwi l l f ur t her
i nsur e good qual i t y j oi nt s i n t he
r egi on of t he bot t ombr acket
shel l . I t i s a good i dea t o
at t ach bot t om br acket gui des
i mmedi at el y af t er l ayi ng t he
seam. Thi s ut i l i zes onl y one
pr eheat of t he bot t ombr acket .
Fol l ow t hese st eps: ( See Fi g.
156)
A. Cl ean and pr ep t he bot t om
br acket shel l and cabl e
gui des f or si l ver br azi ng.
B. Appl y f l ux t o t he i nsi de of
t he shel l as wel l as t he
pl aces wher e t he cabl e gui des
3- 49
CO. I N. wi l l be br azed t o t he
out si de.
C. Pr eheat t he bot t ombr acket
shel l and make sur e al l of
t he f l ux does not r un of f t he
out si de of t he shel l .
D. Lay t he bead ar ound t he
i nsi de f ace of t he shel l
wher e t he t ubes poke t hr ough.
( See Fi g. 156)
E. Put a spot of si l ver wher e
t he r i ght si de bot t ombr acket
gui de wi l l go.
F. Heat up t he r i ght si de gui de,
hol d i t i n pl ace and r eheat
t he spot of si l ver t i l l t he
gui de "nest l es
"
i nt o pl ace.
( See Fi g. 159)
G. Repeat st eps E & F f or t he
l ef t si de gui de. ( See Fi gs.
157 & 158)
37. Af t er t he bot t ombr acket has
cool ed suf f i ci ent l y, cl ean i t up
wi t h hot wat er and aci d.
38. The bot t ombr acket shoul d now be
r et apped wi t h Campagnol o t ool
#721 or equi val ent . ( See
Sut her l and' s Manual f or pr oper
use of cut t i ng t ool s. ) ( See Fi g.
160)
39. The bot t ombr acket shoul d now be
f ace mi l l ed wi t h Campagnol o t ool
#725 or equi val ent . ( See
Sut her l and
'
s Manual f or pr oper
use of cut t i ng t ool s. ) ( See Fi g.
161)
40. A ser i al number shoul d now be
st amped i n t he bot t ombr acket
shel l . Bef or e st ampi ng t he
number , scr ew a set of bot t om
br acket cups i nt o t he bot t om
br acket shel l . Wi t h t he cups i n
pl ace, t he shel l wi l l not def or m
f r omhi t t i ng i t wi t h t he number
st amps. ( Use i magi nat i on f or t he
ser i al number . Put t he dat e t hat
t he f r ame i s r eady f or pai nt i ng
3- 50
CO. I N. or t he number of f r ameset s bui l t
t o dat e. Some cust omer s l i ke t he
i dea of st ampi ng t hei r Soci al
Secur i t y number or dr i ver ' s
l i cense on t he f r ame. ) ( See Fi g.
162)
41. OPTI ONAL - St amp a dupl i cat e
ser i al number on t he st eer i ng
col umn j ust above t he f or k cr own
r ace seat . Thi s not onl y
el i mi nat es conf usi on i f sever al
f r ames ar e bei ng pai nt ed at once
but al so pr ovi des a hi dden ser i al
number i n case of t hef t . ( See
Fi g. 163)
42. I f t he f r ame goes t o a pai nt shop
wi t hi n t he next 48 hour s, not hi ng
el se has t o be done. I f t her e
wi l l be a l onger wai t , et ch t he
sur f ace of t he f r ame ( bot h i nsi de
& out si de) wi t h phosphor i c aci d.
( See Fi g. 164)
3- 51
Tr ansf er r i ng t he st ack
hei ght of t he l ower par t of
t he headset ont o t he dr awi ng
FI G #3 i s i mpor t ant t o t he f r ont
end geomet r y.
Most hi gh qual i t y headset s
wi l l measur e 14mmf or t he
l ower st ack hei ght . ( See
St ep 1- 16)
3-52
FI G #1
The bar e essent i al s f or
maki ng t he dr awi ng i ncl ude;
sui t abl e f l at sur f ace,
st r ai ght - edge, penci l s,
r ul er , er aser , compass,
pr ot r act or , cal i per s, f or k
cr own t o be used, bot t om
head l ug t o be used, and
bot t om1/ 2 of dummy headset .
( See St ep I - 1)
FI G #2
The t hi ckness of t he f or k
cr own must be t r ansf er r ed
ont o t he wor ki ng dr awi ng.
Thi s can be cr i t i cal t o
f r ont end geomet r y. ( See
St ep 1- 15)
The head t ube/ down t ube
i nt er cept poi nt must be
measur ed and t r ansf er r ed t o
FI G. #4 t he dr awi ng. Di f f er ent
br ands of l ugs can var y as
much as 6mm on t hi s
measur ement . ( See St ep
1- 17)
The f i nal dr awi ng shoul d be
kept si mpl e. Any t i me spent
on sket chi ng i n l ugs,
FI G. #5 dr opout s, or even di mensi ons
i s wast ed ef f or t . The
not at i ons her e ar e onl y f or
t he benef i t of t he r eader .
( See St eps 1- 19& 20)
Pi ct ur ed her e ar e t he bar e
essent i al s f or doi ng t he
Gener al Pr ep. Not pi ct ur ed,
FI G. #6 but al so necessar y woul d be
some sor t of hol di ng devi ce
t o secur e t ubes whi l e
cut t i ng, f i l i ng, or mi t er i ng
t hem. A vi se and t ubi ng
cl amps or a Par k st and woul d
suf f i ce. ( See Begi nni ng of
Sect i on I I )
3- 53
Bef or e begi nni ng t he Gener al
Pr ep. , t he t ube set shoul d
be t hor oughl y cl eaned wi t h
FI G. #7 mi ner al spi r i t s. Thi s wi l l
r emove t he gr easy f i l m
( cosmol i ne) used t o pr event
r ust dur i ng st or age.
( Begi nni ng of Sect i on I I )
The i nsi des of t he t ubes
shoul d al so be cl eaned.
Af t er t he t ubes ar e cl eaned
FI G. #8 t hey can r ust r at her
r eadi l y. The f r ame shoul d
be bui l t wi t hi n t wo weeks
f r omt hi s t i me. I f t he
bui l di ng pr ocess i s t o t ake
l onger , oi l t he t ubes down
wi t h a l OWmot or oi l . ( See
Begi nni ng of Sect i on I I )
Scr i bi ng
"
r oughcut " l i nes
at t he bot t omof t he seat
t ube can be done wi t h a
FI G. #9car bi de scr i be. Thi s i s
done at t he but t ed end of
t he si ngl e but t ed seat t ube.
( See St ep I I - 11)
Bef or e begi nni ng t he Gener al
Pr ep. , t he t ube set shoul d
be t hor oughl y cl eaned wi t h
FI G. #7 mi ner al spi r i t s. Thi s wi l l
r emove t he gr easy f i l m
( cosmol i ne) used t o pr event
r ust dur i ng st or age.
( Begi nni ng of Sect i on I I )
The i nsi des of t he t ubes
shoul d al so be cl eaned.
Af t er t he t ubes ar e cl eaned
FI G. #8 t hey can r ust r at her
r eadi l y. The f r ame shoul d
be bui l t wi t hi n t wo weeks
f r omt hi s t i me. I f t he
bui l di ng pr ocess i s t o t ake
l onger , oi l t he t ubes down
wi t h a l OWmot or oi l . ( See
Begi nni ng of Sect i on I I )
Scr i bi ng
"
r ough- cut " l i nes
at t he bot t omof t he seat
t ube can be done wi t h a
FI G. #9car bi de scr i be. Thi s i s
done at t he but t ed end of
t he si ngl e but t ed seat t ube.
( See St ep I I - 11)
3- 54
The bot t omof t he seat t ube
must al so be mi t er ed so t hat
t he down t ube can be
FI G #10 i nser t ed l at er . Rough
mi t er i ng can be done on a
gr i ndi ng wheel t hat has
r ounded edges. ( See St ep
I I - 11)
Scr i bi ng on t he bot t omhead
l ug i s al so meant f or
FI G #11 r oughi ng- i n wor k. Bl ue
l ayout dye can be used i f a
cl ear er l i ne i s desi r ed.
( See St ep 11- 12)
Scr i bi ng a r ough- cut l i ne on
t he t op head l ug i s al so
done wi t h a car bi de scr i be.
FI G #12 These scr i bed l i nes ar e
meant onl y f or r ough
mi t er i ng and pr obabl y wi l l
not be ver y cl ose t o t he
act ual angl es desi r ed. ( See
St ep 11- 13)
3- 55
FI G #13
FI G #14
Angl es can be l i f t ec
di r ect l y of f t he dr awi ng anc
t r ansf er r ed t o t he mi t er
bei ng f i l ed. Thi s wi l l
event ual l y get t he angl e of
t he mi t er t o wi t hi n 1/ 2:
degr ee of t he desi r ed angl e.
( See St ep 11- 12 & 13)
Not e t he use of f r ame bl ocks
t o hol d a pi ece of t ubi ng it
a vi se wi t hout dent i ng.
These can be made by E
machi ne shop of br ass or
al umi num or be homemade
easi l y out of har d mapl e or
oak. ( See St ep I I - 11, I I - 1:
& 11- 13)
FI G #15
The mi t er s i n t he f r ont
t r i angl e can al l be done by
hand wi t h an 8 i nch
hal f - r ound f i l e. At
f act or i es t hi s i s usual l y
done on a Br i dgepor t mi l l
wi t h cost l y f i xt ur i ng. ( See
St ep I I - 11, 12 & 13)
Rot at i ng t he f i l e whi l e
maki ng a f or war d cut wi l l
hel p make a mor e uni f or m
FI G #16 cur ve i n t he mi t er . Not e
how t he t ube i s set at about
60 degr ees so t he f i l e can
be hel d hor i zont al l y. ( See
St ep 11- 12 & 13)
The angl e of t he mi t er can
now be checked wi t h a bevel
pr ot r act or . Thi s coul d al so
FI G #17 be checked wi t h a l ess
expensi ve i nst r ument .
Cr af t sman makes a #9GT 3868
angl e f i nder t hat suf f i ces
ni cel y. ( See St ep 11- 12 &
13)
A machi ni st ' s squar e can be
used t o see i f t he peaks of
t he mi t er ar e at t he same
FI G #18 hei ght . I f one i s l ower ,
t hat means t he mi t er ed t ube
wi l l i nt er sect t he ot her
t ube sl i ght l y t o one si de or
t he ot her . ( See St ep 11- 12
& 13)
3- 57
A ver y i mpor t ant check i s t o
see i f l i ght shi nes t hr ough
t he f i ni shed j oi nt . Gaps
FI G #19ar e one of t he bi ggest
causes of di st or t i on and
def l ect i on i n t he si l ver
br azi ng pr ocess. ( See St ep
11- 12 & 13)
The f i nal check f or a mi t er
i s t o see i f t he desi r ed
angl e i s at t ai ned when t he
FI G #20 j oi nt i s assembl ed. Wi t h a
l ot of pr act i ce, a near l y
per f ect mi t er can be done i n
about 15 mi nut es. ( See St ep
11- 12 & 13)
The bot t omof t he seat t ube
shoul d be checked f or any
unusual l y hi gh spot s i n t he
FI G #21 mi t er when f i ni shed. Thi s
mi t er i s not as cr i t i cal
si nce t he bot t ombr acket
t aps can easi l y cut of f any
hi gh spot s t hat pr ot r ude as
much as 1mm. ( See St ep
I I - 11)
3- 58
Al l t hr ee l ugs and t he
bot t ombr acket shel l must be
r eamed f or a pr oper si l ver
FI G #22 br aze f i t . Ther e shoul d be
about . 004" t o . 006" of
cl ear ance bet ween t he i nsi de
sur f ace of t he l ugs and t he
out er sur f ace of t he t ubes.
Her e t he r eami ng i s bei ng
done wi t h a cyl i ndr i cal
st one mount ed i n a di e
gr i nder . ( See St ep I I - 1 &
11- 2)
Lugs may al so be r eamed wi t h
an 8" hal f r ound f i l e. The
FI G #23 onl y r eal pr obl em t hat
ar i ses i s i n secur el y
hol di ng t he l ugs dur i ng
r eami ng. ( See St ep I I - I &
11- 2)
Af t er r eami ng, t he out si des
of t he l ugs can be pr epar ed.
Al l bl emi shes must be
FI G #24 r emoved t o gi ve t he f r ame a
pr of essi onal l ook. Rough
wor k can be done on a
gr i nder but a 6" hal f r ound
f i l e i s pr ef er r ed. Fi ni sh
f i l i ng i s done wi t h a needl e
f i l e as pi ct ur ed. ( See St ep
11- 4)
3- 59
Fi nal sandi ng shoul d be done
wi t h 80 t o 120 gr i t emer y
cl ot h. I t can be pur chased
FI G #25 i n 1" wi de r ol l s or 9" x 12"
sheet s and t or n t o t he
desi r ed wi dt h. Expect t o
spend at l east 90 mi nut es on
each l ug bef or e t hey ar e
r eady f or si l ver br azi ng.
( See St ep 11- 4)
A Dynaf i l e can gr eat l y speed
up t he pr ocess of f i ni shi ng
l ugs, cr own and bot t om
FI G #26 br acket . Be car ef ul ! I t
goes t hr ough met al at an
i ncr edi bl e speed. Do not
t ouch t he f aces of t he
bot t ombr acket shel l . ( See
St ep 11- 4)
Use a ver y l i ght t ouch i f
t he l ugs ar e t o be f i ni shed
wi t h a Dynaf i l e. I t i s not
FI G #27 necessar y t o f i ni sh t he t op
of t he seat l ug at t hi s
t i me. Don' t squi sh t he
bi nder por t i on of t he seat
l ug i n t he vi se! ( See St ep
11- 4)
When f i ni shi ng t he head
l ugs, do not t ouch t he f aces
wher e t he bear i ng cups wi l l
FI G #28 seat . Al ways use sof t j aws
when cl ampi ng t he l ugs,
bot t om br acket , or f or k
cr own i n t he vi se. ( See
St ep 11- 4)
The f or k cr own must be
r eamed so t he st eer i ng
col umn can be i nser t ed wi t h
FI G #29t he pr oper cl ear ance f or
si l ver br azi ng. Thi s can be
done wi t h a hal f r ound f i l e.
The pr ef er r ed met hod i s t o
use a #28 Chadwi ck
adj ust abl e r eamer as
pi ct ur ed. ( See St ep 11- 3)
Af t er r eami ng t he st eer i ng
col umn shoul d easi l y sl i de
FI G #30 i nt o t he f or k cr own and
wi ggl e back and f or t h
sl i ght l y. The cl ear ance
shoul d be . 004
"
t o . 006".
( See St ep 11- 3)
3- 61
I f t he f or k bl ades ar e not
pr ebent , t hey shoul d be bent
i n a f or k bl ade bender .
FI G #31 Bend t he f i r st one t o specs
and car ef ul l y bend t he
second t o mat ch. A homemade
bender can be made out of
mapl e or oak. ( See St ep
11- 5)
The most accur at e way t o
check t o see i f t he bend i n
FI G #32 f or k bl ades mat ch i s on t he
sur f ace t abl e wi t h a ver ni er
hei ght gauge. ( See St ep
11- 5)
The f i r st bl ade can be l ai d
on t he dr awi ng t o check f or
FI G #33 t he cor r ect amount of bend.
Sl i ght di scr epanci es can be
adj ust ed l at er wi t h t he f or k
j i g. ( See St ep 11- 5)
3- 62
I f t he f or k bl ades and
chai nst ays ar e not al r eady
sl ot t ed t o accept t he
FI G #34 dr opout s, t hi s shoul d be
done at t hi s t i me. Two
par al l el cut s shoul d be made
wi t h a hack saw. The l i t t l e
spur s t hat st i ck up bet ween
t he cut s can be br oken out
wi t h a pai r of needl e nose
pl i er s. These sl ot s shoul d
not be wi de enough t o accept
t he dr opout s yet ! ( See St ep
11- 6 & 8)
The sl ot s shoul d now be
wi dened car ef ul l y so t hat
t he dr opout s wi l l sl i de
FI G #35 snugl y i nt o pl ace. A sl oppy
f i t i s not necessar y her e as
t he si l ver wi l l f or ma
f i l l et al ong t he edges of
t hi s j oi nt . ( See St ep 11- 6
& 8)
I f t he dr opout s don' t f i t
i nt o t he sl ot t ed ends, t he
FI G #36 t abs on t he dr opout s must be
r ounded or f i l ed smal l er .
( See St eps 11- 6 & 8)
3- 63
When i n pl ace, t he dr opout s
shoul d be l oose enough t o
FI G #37 push i n pl ace wi t h t he
f i nger s but t i ght enough t o
hol d t he dr opout i n posi t i on
dur i ng si l ver br azi ng. ( See
St eps 11- 6 & 8)
The f or k bl ades wi t h t he
dr opout s i n t hemshoul d be
hel d up next t o each ot her
FI G #38 and si ght ed acr oss t o see i f
ei t her dr opout i s cocked one
way or t he ot her .
Cor r ect i ons shoul d t hen be
made by f i l i ng t he base of
one of t he sl ot s. At t hi s
poi nt f i l e a smal l ni ck i n
one dr opout t ab and a ni ck
i n t he t op of t he bl ade t hat
mat ches i t . ( See St eps 11- 6
& 8)
Si ght acr oss t he r ear
dr opout s i n t he same manner
as t he f r ont dr opout s. I t
FI G #39i s not necessar y t o mar k
t hemsi nce t he r i ght dr opout
i s di f f er ent and t he r i ght
chai nst ay has al so been
pr epar ed di f f er ent l y. ( See
St ept 11- 6 & 8)
3- 64
The f i r st j oi nt t o be done
i n t he bui l di ng of t he f r ont
t r i angl e i s t he seat t ube
FI G #40 i nt o t he bot t om
br acket . Bef or e si l ver
br azi ng t hi s j oi nt , i t must
be t hor oughl y cl eaned of
dust , oi l & r ust . Fi r st
cl ean wi t h an al kyl i n
cl eaner ( Shakl ee Basi c I i s
a good one) t hen cl ean wi t h
a 10%HC1 aci d sol ut i on
( Sno- Bol wor ks wel l ) . Bl ow
dr y. Aci d cl ean up i s not
r ecommended f or ul t r a l i ght
t ubes i n whi ch case, si mpl y
sand. ( See St ep I I I - 1)
A gener ous amount of f l ux
shoul d be appl i ed t o t he
FI G #41 sur f aces t o be si l ver
br azed. Make sur e t o use
wat er sol ubl e si l ver br azi ng
f l ux. Br ass br azi ng f l ux
wi l l not wor k! ( See St ep
111- 2)
Af t er t he bot t ombr acket /
seat t ube j oi nt has been
cl eaned and f l uxed i t i s put
FI G #42 i nt o t he bot t ombr acket j i g
and si l ver br azed. Thi s j i g
doesn' t have t o be of hi gh
pr eci si on as col d set t i ng
wi l l st i l l be necessar y on
at l east 7 out of 10 j oi nt s
done on t hi s j i g. ( See St ep
111- 5)
3- 65
The bot t ombr acket must now
be t apped wi t h a set of l i ne
FI G #43 t aps. Make sur e t he l ef t
and r i ght si des don' t get
conf used when usi ng Br i t i sh
bot t ombr acket shel l s. ( See
St ep 111- 7)
Face t he bot t ombr acket
bef or e checki ng f or t ube
FI G #44 def l ect i on. Campagnol o and
Gi ppi emme make t he best hand
oper at ed bot t ombr acket f ace
mi l l er s. ( See St ep 111- 8)
Use a gener ous amount of
cut t i ng oi l dur i ng any t ype
of cut t i ng pr ocedur es.
FI G #45 Cut t i ng oi l cont ai ns
chl or i ne and sul phur .
Regul ar mot or oi l wi l l not
do t he j ob pr oper l y. ( See
St ep 111- 8)
3- 66
Def l ect i on of t he seat t ube
as i t l eaves t he bot t om
br acket shel l can be checked
FI G #46 on a st one sur f ace t abl e or
bl anchar d gr ound st eel
pl at e. One r eadi ng i s t aken
cl ose t o t he bot t ombr acket
shel l . Anot her i s t aken at
t he end of t he t ube. An
er r or of 1mmover a span of
1 met er i s accept abl e. ( See
St ep I I I - 9& 47)
A l ess cost l y met hod of
checki ng f or def l ect i on i s
wi t h a bot t om br acket
FI G #47 mi cr omet er . A r eadi ng i s
t aken on each si de of t he
t ube at t he same di st ance
f r omt he bot t ombr acket .
Si nce t hi s i s a f l i p- f l op
met hod t he amount of er r or
i s onl y hal f of t he
di f f er ence of t he t wo
r eadi ngs. ( See St ep I I I - 9&
47)
A needl e f i l e can now be
used t o do f i nal cl ean up of
t he j oi nt . Al l excess
FI G #48 si l ver shoul d be f i l ed away
f r omt he j oi nt . Any bl obs
of si l ver wi l l show t hr ough
t he pai nt j ob. ( See St ep
I I I - 10)
3- 67
Not e how a pi ece of emer y
cl ot h can be br aced wi t h a
FI G #49needl e f i l e. Thi s gi ves t he
emer y cl ot h a st i f f backi ng
whi ch al l ows sandi ng i n
t i ght pl aces. Thi s
t echni que i s much mor e
af f or dabl e t han t he use of
expensi ve r i f f l er f i l es.
( See St ep I I I - 10)
The bot t omhead l ug and head
t ube shoul d be cl eaned
t hor oughl y bef or e si l ver
br azi ng as do al l of t he
FI G #50 ot her j oi nt s. Cl ean any oi l
of f wi t h mi ner al spi r i t s or
l aquer t hi nner . Then t he
t wo pi eces shoul d be cl eaned
i n hot wat er and a mi l d HC1
aci d sol ut i on. Pr oper
vent i l at i on i s a must ! ( See
St ep I I I - 11)
About 1mmof t he head t ube
shoul d pr ot r ude t hr ough t he
bot t om head l ug. Thi s
FI G #51 pr ovi des a sl i ght r i mwhi ch
si l ver can be dr opped ont o.
Wi t h pr act i ce, al most al l of
t he si l ver necessar y f or
t hi s j oi nt can be pul l ed up
f r omt hi s r i m. ( See St ep
I I I - 14 & 15)
3- 68
Put t he mi t er ed down t ube
i nt o t he f i ni shed j oi nt .
See how cl ose t he compl et e
FI G #52 j oi nt wi l l come t o t he
dr awi ng. Col d set t i ng may
be necessar y bef or e doi ng
t he f i nal br azi ng on t hi s
j oi nt . When t he angl e i s
cor r ect , cl ean and f l ux t he
pi eces. ( See St ep 111- 18)
Tack t he poi nt s of t he l ugs
f i r st . Af t er checki ng t he
FI G #53 angl e agai nst t he dr awi ng
and col d set t i ng as
necessar y, f i ni sh t he j oi nt .
( See St ep I I I - 21)
Af t er t he bot t omhead l ug
j oi nt i s compl et ed, i t must
be checked f or t he pr oper
FI G #54 angl e agai n. I f col d
set t i ng i s necessar y,
r ei nf or ce t he down t ube wi t h
a sol i d st eel bar t o keep i t
f r omki nki ng. Thi s i s t he
most i mpor t ant j oi nt i n t he
bi ke. I f i t ' s not accur at e,
t he f r ont end wi l l be
geomet r i cal l y i ncor r ect .
( See St ep 111- 23)
3- 69
Bef or e pr oceedi ng wi t h t he
bot t om br acket / down t ube
j oi nt , t he down t ube wi l l
FI G #55 usual l y have t o be r ough cut
t o about 2cmt oo l ong so
t hat t he head t ube/ seat
t ube/ down t ube conf i gur at i on
can be l oosel y assembl ed.
Fi ndi ng t he r ough l engt h of
t he down t ube can be most
easi l y f ound by suspendi ng
t he f r ame t ubes above t he
dr awi ng on V bl ocks and
t r ansf er r i ng measur ement s up
f r omt he dr awi ng. ( See St ep
I I I - 28)
Assembl e t he head t ube/ down
t ube/ seat t ube ( HT/ DT/ ST)
conf i gur at i on and si t uat e i t
FI G #56 di r ect l y above t he dr awi ng.
V bl ocks and a machi ni st ' s
squar e can be used t o get
t he pr oper l ocat i on. Now
mar k t he down t ube f or t he
mi t er wi t h a car bi de scr i be.
( See St ep 111- 32)
Anot her mar k must be made
al ong t he out si de of t he
bot t ombr acket shel l . Thi s
FI G #57 mar k i s necessar y because
when t he HT/ DT/ ST i s i n t he
bot t om br acket j i g, t he
i nsi de of t he bot t ombr acket
shel l wi l l not be vi si bl e t o
check f or f l ush. When
el evat i ng t he f r ame above
t he dr awi ng, be sur e t o
al l ow f or t he di f f er ent
di amet er of t he head t ube.
( See St ep 111- 33)
Af t er t he j oi nt i s mi t er ed
and cleaned i t may be
el evat ed above t he dr awi ng
FI G #58 agai n. The machi ni st ' s
squar e i s t hen used t o see
i f al l l i nes of t he dr awi ng
l i ne up wi t h t he edges of
t he f r ame t ubes. Tol er ances
f or l i ni ng t hi s up would be
t he t hi ckness of a l i ne over
a span of 50cm. ( See St ep
111- 37 & 49)
When t he HT/ DT/ ST i s i n
position above t he dr awi ng,
t ake a measur ement f r omt he
FI G #59f r ont of t he t op of t he seat
t ube t o t he f r ont of t he t op
of t he head t ube. I t ' s a
good i dea t o have a hel per
at t hi s poi nt t o st abi l i ze
t he f r ame whi l e measur i ng.
( See St ep 111- 31 & 49)
Make not e of t he measur ement
j ust t aken. Do not cut t he
FI G #60 t ops of t hese t ubes of f t i l l
t hi s measur ement has been
ut i l i zed! ( See St ep 111- 31
& 49)
3- 71
The HT/ DT/ ST may now be
cl eaned at t he j oi nt and
assembl ed i nt o t he bot t om
FI G #61 br acket j i g. Not e t he use
of t he head t ube st abi l i zer
bar now. Thi s i s al so when
t he 58cmmeasur ement f r om
t he l ast st ep i s ut i l i zed.
( 58cm mer el y bei ng t hi s
par t i cul ar exampl e) ( See
St eps 111- 40, 41 & 44)
The down t ube/ bot t ombr acket
j oi nt shoul d be pi nned
bef or e si l ver br azi ng. A
FI G #62 smal l nai l i s sui t abl e.
J ust make sur e t he f i t of
t he nai l i n t he hol e i s
t i ght . Thi s wi l l keep t he
mar k i n pl ace t hat was
et ched al ong t he out si de of
t he bot t ombr acket shel l .
( See St ep 111- 43)
Af t er cl ean up and f l uxi ng,
t he j oi nt can be si l ver
br azed. Af t er t hi s j oi nt
FI G #63 cool s, i t must be checked
f or al i gnment wi t h t he
bot t ombr acket mi cr omet er
and col d set as necessar y.
Use t he down t ube pr ot ect or
sheat h t o pr event ki nki ng.
Head t ube t wi st CANNOT be
r emoved at t hi s poi nt ! ! !
( See St ep 111- 45)
3- 72
Af t er any necessar y col d
set t i ng el evat e t he f r ame
over t he dr awi ng. At t hi s
FI G #64 t i me t r ansf er t he l ocat i on
of t he t op t ube up f r omt he
dr awi ng ont o t he backsi de of
t he head t ube. Thi s mar k
shoul d be made wi t h a
car bi de scr i be. ( See St ep
111- 51)
Af t er l ocat i ng t he t op t ube
on t he backsi de of t he head
t ube, mar k t he l ocat i on f or
FI G #65 t he ai r expansi on hol e.
Thi s can be ei t her
t r ansf er r ed up f r omt he
dr awi ng or t he l ug can be
cent er ed on t he pr evi ous
mar ks t o eyebal l t he
l ocat i on. ( See St ep 111- 53)
Her e i s a cl ose- up shot of
t he 1/ 2
"
ai r expansi on hol e
and t he t wo mar ks whi ch show
FI G #66 t he l ocat i on of t he t op
t ube. A 1/ 2
"
ai r expansi on
hol e i s an absol ut e must t o
i nsur e good ci r cul at i on on
t he i nsi des of t he t ubes
dur i ng met al t r eat ment .
Ther e shoul d be one at each
end of t he t op t ube. ( See
St ep 111- 52, 54 & 66)
3- 73
The t op t ube must now be cut
t o r ough l engt h. Measur e
FI G #67 t he di st ance f r omt he f r ont
of t he seat t ube t o t he back
of t he head t ube al ong t he
t op of t he t op t ube. ( The
f r ame bei ng bui l t i n t hi s
pi ct ur e has a 49cmST. )
Her e t he scr i be i s
i ndi cat i ng wher e t he
FI G #68 measur ement shoul d be t aken
f r om. ( The f r ame bei ng
bui l t i n t hi s pi ct ur e has
a 56cm ST. ) ( See St ep
111- 56)
Lay t he met er st i ck al ong
t he t op edge of t he t op t ube
wi t h zer o at t he cr ot ch of
FI G #69t he mi t er t hat was al r eady
done. Now mar k f or t he cut .
I t must be cut 1cml onger
t han t he measur ement t aken.
( See St eps 111- 58 & 59)
3- 74
The mi t er s can be checked t o
see i f t hey ar e bot h i n t he
same pl ane by hol di ng a 1
FI G #70 1/ 4
"
t ube at one end and a 1
1/ 8
"
t ube at t he ot her end.
Then si ght down t he t ube t o
see i f bot h pi eces ar e i n
one pl ane. The t op t ube i s
t he most di f f i cul t t ube t o
f i t i n t he ent i r e f r ame.
( See St ep I I I - 61)
The t op t ube shoul d j ust
dr op i nt o pl ace wi t hout any
f or ce at al l . Any f or ce
FI G #71 used t o put t he t op t ube i n
pl ace wi l l push t he head
t ube and seat t ube apar t ,
t hus al t er i ng t he geomet r y
of t he f r ont t r i angl e. ( See
St ep 111- 62)
Thi s i s t he j oi nt t hat was
mi t er ed dur i ng t he gener al
pr epar at i on. I t shoul d not
FI G #72 be al t er ed at al l as t he t op
t ube i s bei ng f i t t ed. ( Not e
t he pi ece of maski ng t ape.
I t was put i n pl ace dur i ng
t he gen. pr ep. t o show whi ch
end was mi t er ed f i r st . )
( See St ep 111- 62)
The seat t ube/ t op t ube mi t er
i s now f i ni shed. I t must be
a cl ose and cl ean f i t and
FI G #73 cannot be f or ced i nt o pl ace.
Fi t t i ng a t op t ube by an
exper i enced bui l der shoul d
t ake 20- 30 mi nut es. ( See
St ep 111- 62)
Rough cut t i ng t he t ops of
t he seat and head t ubes can
be done any t i me af t er t he
FI G #74 HT/ DT/ ST comes out of t he
bot t ombr acket j i g. About
5mmshoul d pr ot r ude beyond
t he t op of t he l ugs af t er
r ough cut t i ng. Thi s
pr ot r udi ng r i mi s a handy
ar ea t o dr op si l ver ont o
dur i ng t he si l ver br azi ng.
( See St ep 111- 63)
J i ggi ng f or t op t ube
i nst al l at i on i s r at her
si mpl e. The l ugs do most of
FI G #75 t he wor k of hol di ng t hi ngs
i n pl ace. The modi f i ed bar
cl amp i s used t o make t he
ends of t he t op t ube bot t om
out agai nst t he seat and
head t ubes. ( Thi s f r ame i s
a mount ai n bi ke f r ame. Not e
t he l ugl ess const r uct i on
ar ound t he bot t ombr acket . )
( See St ep 111- 71 & 74)
3- 76
Her e i s a cl ose- up of
modi f i ed C- cl amp #1. Not e
FI G #76 how i t hol ds t he poi nt s of
t he l ug agai nst t he t op
t ube. ( See St ep 111- 75)
Her e i s a cl ose- up of
modi f i ed C- cl amp #2. Not e
FI G #77 how i t hol ds t he t op t ube i n
pl ace so i t won' t cr eep up
t he seat t ube. ( See St eps
111- 72)
Af t er t he t op t ube i s
i nst al l ed, t he head t ube i s
r eamed and f ace mi l l ed. I t
FI G #78 i s r ecommended t o f ace t he
poor er of t he t wo ends
f i r st . That woul d be t he
t op as t he bot t om i s a
f act or y f i ni shed end. Thi s
al l ows t he cent er i ng cone of
t he t ool t o l ocat e on a
semi - f i ni shed f ace. Mi l l
onl y t i l l a smoot h sur f ace
i s obt ai ned. ( See St ep
111- 81)
3- 77
Now t he bot t omf ace can be
mi l l ed. Agai n, mi l l onl y
t i l l a smoot h sur f ace i s
FI G #79obt ai ned. Use pl ent y of
cut t i ng oi l and t ake onl y
l i ght cut s wi t h t he spr i ng
t ensi on set l i ght t o medi um.
Mi l l i ng t oo much of f t he
bot t omhead l ug can al t er
f r ont end geomet r y sl i ght l y.
( See St ep 111- 82)
The f i r st st ep i n bui l di ng a
f or k i s t o mar k t he st eer i ng
col umn at a r ough cut
FI G #80 l engt h. Thi s can be done by
i nst al l i ng t he dummy
headset , col umn, and cr own
i n t he newl y compl et ed f r ont
t r i angl e and scr i bi ng a l i ne
as shown. ( See checkl i st
f or amount s t hat can be
saf el y cut of f . ) ( See St eps
I V- 9, 10, 11, & 12)
When cut t i ng t he col umn f or
r ough l engt h, cut about 2mm
FI G #81 bel ow t he l i ne. Thi s wi l l
l eave a l i t t l e r i mt o dr op
si l ver on dur i ng si l ver
br azi ng. ( See St ep I V- 10,
11 & 12)
The col umn and cr own must be
cl eaned f or si l ver br azi ng.
Bl ue l ayout dye i s bei ng
FI G #82 r emoved her e by sandi ng.
The pi eces shoul d t hen be
cl eaned i n aci d as ot her
j oi nt s ar e. ( See St ep
I V- 13)
Fl ux bot h pi eces gener ousl y.
Si nce t hi s i s a massi ve
FI G #83 ( t hi ck) j oi nt , a l ot of f l ux
wi l l pr obabl y dr i p of f
dur i ng t he l onger pr eheat .
( See St ep I V- 14 & 15)
Pl ace a gener ous amount of
f l ux r i ght on t op of t he
FI G #84 cr own as wel l . Thi s wi l l
gi ve a r eser ve of f l ux t o
dr aw upon as ot her f l ux
dr i ps and i s l ost . ( See
St ep I V- 14 & 15)
3- 79
Dur i ng si l ver br azi ng add
si l ver t o t he smal l r i m
pr ot r udi ng beyond t he
FI G #85 bot t omof t he cr own. I f t he
cr own has a pr edr i l l ed br ake
hol e, do not add si l ver
t her e as sur f ace t ensi on can
hol d t he si l ver at t hat
poi nt and i t wi l l not dr aw
pr oper l y. ( See St eps I I I - 15
& 16)
When si l ver has dr awn cl ear
t hr ough t he j oi nt and a r i ng
of si l ver can be seen al l
FI G #86 ar ound t he t op of t he
bear i ng seat , t he j oi nt i s
done. Al l ow i t t o cool
bef or e cl eani ng t he f l ux of f
wi t h wat er . ( Don' t hol d
your hand over t he t op of
t he st eer i ng col umn when
submer gi ng i n wat er ) ( See
St eps I I I - 15 & 17)
A 10" hal f r ound f i l e wi l l
r emove t he 2mmr i mar ound
t he bot t omof t he cr own.
FI G #87 Then swi t ch t o a 6" hal f
r ound t o r emove t he l ar ge
f i l e mar ks. A gr i ndi ng
wheel i s not hi ghl y
r ecommended f or t hi s j ob as
i t wi l l t end t o gr i nd f acet s
t hat wi l l have t o be r emoved
af t er war ds. ( See St ep
I V- 18)
3- 80
I L
Fi ni sh f i l i ng can be done
wi t h a hal f r ound needl e
FI G #88 f i l e. Af t er t hi s, sandi ng
can be done as an opt i onal
st ep. ( See St ep I V- 18)
I f a pr edr i l l ed cr own was
used, l ocat i ng t he br ake
hol e i s si mpl e. Do not
FI G #89set t l e f or an undr i l l ed
cr own unl ess a br ake hol e
wi l l not be dr i l l ed. Some
cr owns ar e di mpl ed f or t he
br ake hol e whi ch i s al so
accept abl e. ( See St ep
I V- 21)
I f an al i en st yl e br ake bol t
wi l l be used, t he backsi de
of t he 1/ 4" br ake hol e needs
FI G #90 t o be count er bor ed wi t h a
13/ 32" count er bor e wi t h a
1/ 4" pi l ot . Count er bor e t o
a dept h of 2mm. The 1/ 4"
hol e i n t he backsi de must
now be dr i l l ed out t o
21/ 64". Do not dr i l l t he
1/ 4" hol e i n t he f r ont of
t he cr own! Do t hi s
oper at i on on a dr i l l pr ess or
pr ef er abl y a mi l l i ng
machi ne. ( See St ep I V- 22)
3- 81
I nst al l a f or kcr own r ace
mi l l i ng t ool as pi ct ur ed.
FI G #91 Not e how par t of t he dummy
headset can be used t o get
ext r a spaci ng. ( See St ep
I V- 23)
Whi l e hol di ng t he assembl y
upsi de down, appl y cut t i ng
FI G #92 oi l t o t he cr own r ace ar ea.
Then cl amp i n vi se as shown.
( See St ep I V- 23)
Thi s t ool usual l y r equi r es a
gr eat deal of downwar d
pr essur e. I n f act , spr i ng
FI G #93 pr essur e may not even be
enough. Cut t i l l a smoot h
sur f ace can be seen al l
ar ound t he cr own r ace ar ea.
( See St ep I V- 23)
3- 82
A f l at must be f i l ed on t he
back si de of t he t op of t he
t hr eaded por t i on of t he
FI G #94 st eer i ng col umn. Most
cr owns ar e r ever si bl e so t he
f l at wi l l det er mi ne whi ch
si de of t he cr own/ col umn i s
t he back. Aer o cr owns have
t he shar p t r ai l i ng edge at
t he back. Count er bor ed
cr owns have t he count er bor e
at t he back. ( See St ep
I V- 20)
A washer wi t h a f l at ( Not a
key) shoul d be kept on hand
f or f i t t i ng. Zeus makes an
FI G #95 excel l ent al l oy washer wi t h
a f l at on i t f or t hi s
pur pose. The f i t shoul d be
snug ( al most a f or ce f i t ) .
( See St ep I V- 20)
The f or k t i ps may be si l ver
br azed i n pl ace next . They
shoul d have been al r eady f i t
FI G #96 t o t he bl ades i n t he gen.
pr ep. Si nce t he dr opout i s
f ar t hi cker t han t he bl ade
about 60 t o 70 per cent of
t he heat shoul d be on t he
dr opout . ( See St ep I V- 3, 4,
& 5)
3- 83
Each bl ade must have t wo ai r
expansi on hol es. One i s
dr i l l ed about 1cmup f r om
FI G #97 t he dr opout on t he i nsi de
f ace of t he f or k bl ade.
Dr i l l i t on t he opposi t e
si de of t he name pr i nt ed on
t he dr opout ! ( See St ep
I V- 30)
Some cr owns, l i ke t he
Amer i can made Henr y J ames,
i nt egr at e ai r expansi on
FI G #98 hol es i nt o t he cr own i t sel f .
I f usi ng a cr own wi t hout
t hese hol es, t he ot her ai r
hol e shoul d be dr i l l ed about
2cmdown f r omt he cr own on
t he i nsi de f ace of t he
bl ade. These hol es shoul d
be dr i l l ed af t er t he bl ades
ar e cut t o l engt h.
Test t he bl ades f or a pr oper
f i t wi t h t he cr own. I t
shoul d be t he same . 004"
FI G #99cl ear ance as wi t h al l ot her
j oi nt s so f ar . I nvest ment
cast cr owns usual l y have a
bet t er f i t at t hi s poi nt .
( See St ep I V- 24)
3-84
Many t i mes t he oval cr oss
sect i on of t he f or k bl ade
i s not qui t e r i ght t o f i t
FI G #100 pr oper l y ont o t he cr own.
I f t hi s i s t he case,
squeeze t he bl ades ver y
sl i ght l y i n t he sof t j aws
of t he vi se. ( See St ep
I V- 24)
I f t he bl ades st i l l don' t
f i t pr oper l y on t he cr own,
t hen f i l e t he cr own at t he
FI G #101 cont act ar ea. I n t he case
of over l appi ng cr owns,
car ef ul l y gr i nd t he i nsi de
of t he openi ng. NEVER
gr i nd mat er i al of f t he
bl ades t o obt ai n t he pr oper
f i t ! ! ! ( See St ep I V- 24)
The dummy br ake may be used
t o cal cul at e how much
shoul d be cut of f t he f or k
FI G #102 bl ades. Si mpl y measur e
f r omt he desi r ed hol e i n
t he dummy br ake t o t he
cent er of t he r i msi dewal l .
That i s t he amount t o cut
of f t he bl ades. I mpor t ant :
Regul ar or shor t r each
br akes shoul d have been
desi gned i nt o t he dr awi ng
and not changed at t hi s
poi nt . Thi s can have a
consi der abl e ef f ect on
f r ont end geomet r y. ( See
St ep I V- 25)
3-85
Anot her way t o f i gur e out
how much t o cut of f t he
bl ades i s t o measur e f r om
FI G #103 t he under si de of t he cr own
t o be used t o t he t op of
t he t i r e t o be used. Fr om
t hat measur ement subt r act
t he cl ear ance t hat was
f i gur ed i nt o t he dr awi ng.
That l eaves t he amount t o
be cut of f . Thi s amount of
cl ear ance cannot be changed
f r omt hat whi ch appear s on
t he dr awi ng. ( See St ep
I V- 25)
Mar k t he l ocat i on f or t he
cut on t he si de of t he
bl ade. Cut t he bl ades f r om
FI G #104 si de t o si de not f r ont t o
back. Thi s wi l l gi ve t he
saw l ess chance t o wander .
I t may be necessar y t o gi ve
t he cut a l i t t l e upwar d
sl ant on some i nser t ed
cr owns t o i nsur e a good
f i t . ( See St ep I V- 25 & 26)
Her e t he bl ades ar e cut t o
l engt h. Not e how t he t i r e
FI G #105 and r i measi l y set i n t he
dead cent er posi t i on. ( See
St ep I V- 28)
3- 86
I f usi ng an i nser t ed cr own,
t he f i t of t he t ops of t he
bl ades agai nst t he cr own i s
FI G #106 cr i t i cal . Wi t h a gap, as
shown, hot shor t ness wi l l
cause t he gap t o cl ose.
Thi s wi l l t hr ow of f l at er al
al i gnment of t he t i ps by as
much as 5mm. ( See St ep
I V- 28)
Thi s pi ct ur e shows a good
FI G #I 07 f i t . ( See St ep I V- 28)
Bef or e t he f or k goes i nt o
t he j i g, i t must have a
good f i t bet ween t he
FI G #108 dr opout and t he hub. A
poor f i t , as shown, wi l l
put spr i ng t ensi on on t he
f or k whi l e i t i s i n t he
j i g. When r el eased, i t
wi l l seek t he shape i t
want s. ( See St ep I V- 29)
3- 87
Thi s pi ct ur e shows a good
FI G #109f i t af t er col d set t i ng.
( See St ep I V- 29)
Set t he f or k j i g f or t he
cor r ect amount of r ake. To
get t he r i ght hei ght f or
FI G #110 t he t op of t he axl e add up
t he f ol l owi ng val ues:
1- Hei ght of cent er l i ne of
col umn above t he sur f ace of
t he j i g, 2- Amount of r ake
desi r ed, 3- Radi us of axl e.
Thi s wi l l gi ve t he r eadi ng
t o set t he ver ni er hei ght
gauge at . ( See St ep I V- 33)
Af t er t he j oi nt s t o be done
have been cl eaned and
f l uxed, i nst al l t he f or k i n
FI G #111 t he j i g. Wi t h a br ass
hammer and a bl ock of wood
set t he cr own/ col umn f i r ml y
agai nst t he t ops of t he
bl ades as pi ct ur ed. ( See
St ep I V- 36)
The dr opout s shoul d be
l i ght l y t apped wi t h a br ass
FI G #112 hammer bef or e t he qui ck
r el ease i s t i ght ened. Thi s
wi l l i nsur e t hat t hey ar e
f ul l y i n pl ace. ( See St ep
I V- 35)
Now r est t he f or k t wi st
gauge acr oss t he f or k
bl ades cl ose t o t he cr own.
FI G #113 Do not put i t on t he
t aper ed por t i on of t he
bl ades. Zer o out t he
i ndi cat or di al and t ake a
r eadi ng. Now f l i p t he
gauge over and t ake anot her
r eadi ng. ( See St ep I V- 37)
Her e t he f ace of t he f or k
t wi st gauge can be seen.
Not e how cl ose t o t he cr own
FI G #114 t he gauge i s pl aced. For
t he sake of cl ar i t y, many
of t hese phot os don' t have
f l ux appl i ed yet . ( See
St ep I V- 37)
3- 89
To get t he same r eadi ng on
bot h si des of t he f or k, t he
cr own must be t wi st ed.
FI G #115 Thi s can be done wi t h a
Phi l l i ps scr ewdr i ver whi ch
has a 1/ 4" shaf t . Put t he
scr ewdr i ver shaf t t hr ough
t he br ake hol e, l oosen t he
cl amp on t he col umn, t wi st
as necessar y, and t i ght en
t he cl amp. ( See St ep
I V- 37)
The f or k i s now r eady f or
FI G #116 si l ver br azi ng. Keep a
maj or i t y of t he heat on t he
cr own- - not t he bl ades.
( See St ep I V- 39)
The backsi de of t he f or k
can be done t hr ough t he
wi ndow i n t he back of t he
FI G #117 j i g. Use of any mat er i al
l ess t han 1/ 2" al umi num
pl at e or 3/ 8" st eel pl at e
f or t hi s j i g i s not
advi sed. ( See St ep I V- 39)
3- 90
When t he f or k i s r emoved
f r omt he j i g, i t shoul d be
checked f or al i gnment by
FI G #118 i nst al l i ng a f r amebui l der ' s
wheel . Look f or a
di f f er ence i n cl ear ance
bet ween t he r i mand bl ades
on each si de. Somet i mes
col d set t i ng i n a Par k f or k
j i g
i s necessar y. The
dr opout al i gnment shoul d be
checked wi t h a set of
f i gur e "H" t ool s ( pi ct ur ed
her e) ( See St ep I V- 42)
The r ear end j i g i s
pi ct ur ed her e. I n or der t o
use i t , t he f r ont t r i angl e
FI G #119and f or k must be compl et ed.
A dummy headset must be
avai l abl e, and i f t he t op
t ube has not been desi gned
l evel - - t he exact sl ope as
per t he dr awi ng must be
abl e t o be measur ed.
Bef or e begi nni ng wor k wi t h
t hi s j i g, i t shoul d be
l evel ed. ( See St ep V- 1)
When t he par t i al l y
compl et ed f r ame i s
i nst al l ed i n t he r ear end
FI G #120 j i g, a st r ai ght - edge can be
used on edge t o scr i be
cent er l i nes on t he t ubes.
Thi s wi l l be used t o l ocat e
t he t op t ube i n t he l evel ed
j i g. Bl ue l ayout dye can
be used t o make t he l i nes
mor e l egi bl e. ( See St ep
V- 5)
3- 91
Scr i be l i nes on t he r ear
FI G #121 por t i on of t he f r ont
t r i angl e as wel l . ( See
St ep V- 6)
Usi ng t he l i ne scr i bed i n
FI G #122 t he pr evi ous st ep, measur e
f r omt he base of t he j i g t o
t he l i ne. ( See St ep V- 8)
Now measur e t he di st ance
f r omt he base t o t he l i ne
at t he f r ont por t i on of t he
FI G #123 t op t ube. The bot t om
br acket wi l l have t o be
r ai sed or l ower ed t o get
t he measur ement s at each
end of t he t op t ube t o
mat ch. Thi s may t ake 3 or
4 t r i es bef or e bot h
r eadi ngs ar e t he same.
( See St ep V- 7)
3- 92
A st r i ng can be dr awn t i ght
bet ween t he dummy axl es on
t he j i g t o l ocat e t he axl e
FI G. #124 l i ne. Now t he bot t om
br acket dr op can be
measur ed. See t hat i t
mat ches t he dr awi ng. I f
mi nor mi st akes have been
made i n t he const r uct i on of
t he f r ame, some er r or can
be t aken up at t hi s
l ocat i on. ( See St ep V- 10)
Bef or e checki ng t he t ube
angl es, make sur e t he j i g
FI G #125 i s l evel . A si mpl e
pr ot r act or l evel wi t h a
magnet i c base i s
suf f i ci ent . ( See St ep
V- 10)
Usi ng t he same pr ot r act or
l evel , check t he t op t ube
angl e. Thi s measur ement i s
FI G #126 onl y f or sel f sat i sf act i on.
I f t he angl es ar e of f f r om
t he dr awi ng, i t i s t oo l at e
t o change t hi ngs. ( See
St ep V- 10)
3-93
Her e agai n t hese
FI G #127 measur ement s ar e j ust a
spot check. ( See St ep
V- 10)
Thi s i s t he cr i t i cal angl e.
I t must be wi t hi n 1/ 2
degr ee of what was set out
f or . As bef or e, t hi s i s
FI G #128 r eal l y t oo l at e t o change
t hi ngs. HOWEVER, a qui ck
f i x way t o t r y t o adj ust an
i ncor r ect head angl e woul d
be t o r ai se or l ower t he
bot t ombr acket . Thi s i s a
l ast di t ch met hod and i s
somewhat f r owned upon by
t he aut hor ! ( See St ep
V- 10)
When t he f r ont t r i angl e,
f or k, and dummy headset ar e
al l i n pl ace - - wor k can
FI G #129begi n on t he r ear t r i angl e.
Begi n by sl i di ng t he r ear
axl e post t o t he desi r ed
l engt h f or t he r ear
t r i angl e. I MPORTANT:
Check f or t i r e cl ear ance
behi nd t he seat t ube. As a
gener al r ul e; 27" t i r es
have a r adi us of 34cmand
700c t i r es have a r adi us of
33. 7cm. ( See St ep V- 16)
Measur e t he r ough l engt h
f or t he chai nst ays. Thi s
shoul d be measur ed f r om
FI G #130 about 1/ 3 of t he way i nt o
t he bot t ombr acket shel l t o
t he cent er poi nt of t he
r ear axl e. ( See St ep V- 17)
The r ough cut chai nst ay
l engt h i s t hen t r ansf er r ed
t o t he chai nst ay wi t h t he
FI G #131 dr opout br azed i nt o pl ace.
Al l ow some l eeway - - cut
t he chai nst ays about 1cm
l onger t han necessar y.
( See St ep V- 17)
The chai nst ays pr obabl y
wi l l not f i t i nt o t he
openi ngs of t he bot t om
FI G #132 br acket shel l yet . Reami ng
wi t h a 5/ 8" cyl i ndr i cal
st one wi l l be necessar y. A
di e gr i nder i s t he best
t ool f or t he j ob. Ai mt he
t ai l of t he di e gr i nder
t owar d t he dr opout and t r y
not t o
"
r ock
"
t he st one t oo
much. ( See St ep V- 18 & 19)
3- 95
Her e t he chai nst ays ar e
bei ng scr i bed f or t he
f i ni shi ng cut . The
FI G #133 f i ni shi ng cut can be done
on t he bench gr i nder . A
r eal l y f i ne mi t er i s not
necessar y her e as t he
bot t ombr acket t aps wi l l
r emove as much as 1mmof
excess t hat pr ot r udes i nt o
t he shel l . ( See St ep V- 21)
The seat st ays must be
pr epar ed f or i nst al l at i on.
I f t he ends ar e not al r eady
FI G #134 domed and sl ot t ed, t hi s
must be done as pi ct ur ed.
Not e how t he st ay on t he
spr ocket si de has a
shor t ened t i p on one si de.
Thi s i s done f or added
chai n cl ear ance. I t woul d
be a good i dea t o wr ap a
pi ece of maski ng t ape
ar ound each st ay and mar k
t hemR & L and not e whi ch
i s t he i nsi de f ace of each.
( See St ep V- 27, 28 & V- 10)
Ther e ar e a mul t i t ude of
ways t o f i ni sh t he t ops of
t he st ays. The easi est way
FI G #135 i s t o use t he r eady made
sl ugs as pi ct ur ed. Thi s
par t i cul ar bi ke wi l l have
t he sl ugs modi f i ed i nt o a
f ast back conf i gur at i on.
The seat st ays must be
compl et el y f i ni shed
pr oduct s wi t h 2 ai r
expansi on hol es i n each
bef or e t hey can be
i nst al l ed. A good f i t
wi t hout sl op i s cr i t i cal .
( See St ep V- 30)
3- 96
When t he seat st ays ar e i n
pl ace and al l j oi nt s
FI G #136 cl eaned and f l uxed, br azi ng
can begi n. Fi r st "t ack"
t he chai nst ays. ( See St ep
V- 48)
Next , move t o t he dr opout /
seat st ay j oi nt s. Keep
FI G #137 60- 70%of t he heat on t he
dr opout due t o t he
di f f er ence i n t hi ckness of
t he t wo met al s. ( See St ep
V- 49)
At t ach seat st ays t o t he
seat l ug. For var i at i ons
i n seat cl ust er
FI G #138 conf i gur at i ons see t he
var i at i ons sect i on of t hi s
book. Neat cl ean br azi ng
i s necessar y on t he seat
cl ust er . Due t o al l of t he
cont our s i n t hi s ar ea,
cl ean up wi t h f i l es and
emer y cl ot h i s di f f i cul t .
( See St ep V- 50)
3- 97
Af t er r emovi ng t he near l y
FI G #139compl et ed f r ame f r omt he
r ear end j i g, t he br azi ng
of t he chai nst ays can be
f i ni shed. ( See St ep V- 52)
The seat t ube must be
cl eaned out t hor oughl y and
t hen r eamed f or an easy
FI G #140 sl i de f i t of t he seat post
wi t h a Chadwi ck #28
adj ust abl e r eamer . A
f i ni shi ng t ouch can be done
by honi ng t he seat t ube
wi t h a br ake cyl i nder hone.
Be car ef ul not t o go
over si zed on t hi s
oper at i on! ! ! Use a 27. 2
seat post as a gauge t o
check f or f i t . ( See St ep
V- 54)
I f a sur f ace t abl e and
necessar y f i xt ur es ar e not
avai l abl e, t he al i gnment of
FI G #141 t he f r ont and r ear t r i angl e
pl anes can be checked by
at t achi ng a st r i ng t o one
dr opout , wr appi ng i t
t i ght l y ar ound t he head
t ube and at t achi ng i t t o
t he ot her dr opout . Measur e
t he gap bet ween t he st r i ng
and seat t ubes on bot h
si des. Er r or i s doubl ed.
. 5mmi s accept abl e. ( See
St eps VI - 1, 2 & 33)
3- 98
Af t er r eami ng t he seat
t ube, a st r ess r el i ef hol e
FI G #142 shoul d be dr i l l ed wher e t he
bot t omof t he bi nder sl ot
wi l l come. 7/ 32" i s a good
si ze t o use. ( See St ep
V- 55)
The bi nder sl ot can be cut
wi t h an abr asi ve cut - of f
wheel mount ed on an ar bor
FI G #143 and chucked i n a di e
gr i nder . These cut - of f
wheel s ar e avai l abl e at
many aut o suppl y st or es.
I MPORTANT: Be sur e t he RPM
r at i ng of t he wheel mat ches
or exceeds t he RPMof t he
di e gr i nder . USE SAFETY
GLASSES DURI NG THI S
OPERATI ON! ! ! ( See St ep
V- 56)
Br i dges and br aze- ons can
now be i nst al l ed. Her e i s
an ar r ay of pi eces t o go on
FI G #144 a st andar d r aci ng or spor t
t our i ng f r ame. Tour i ng
f r ames of t en r equi r e many
mor e br aze- ons. ( See
Begi nni ng of Sect i on VI )
3- 99
Fi r st t he br ake br i dge i s
i nst al l ed. Not e t he use of
t he dummy r ear wheel t o
FI G #145 l ocat e t he posi t i on f or t he
br i dge. Thi s f i t must be a
ver y snug f i t wi t h a
mi ni mumof gaps. A l oose
f i t or gaps wi l l al l ow t he
dr opout s t o pul l t oget her
dur i ng cool i ng. ( See St ep
VI - 5, 6 & 7)
Some br ake br i dges must be
br azed t oget her bef or e
i nst al l at i on. Some ar e
FI G #146 desi gned so t hat no
assembl y i s needed bef or e
i nst al l i ng. Make sur e t hat
what ever ki nd i s bei ng
used, al l owance i s made f or
hot ai r t o escape t hr ough
ai r expansi on hol es. ( See
St ep VI - 12)
I t i s a good i dea t o br aze
i n t he br i dges i n an
upsi de- down posi t i on. Thi s
FI G #147 el i mi nat es t he need f or
j i ggi ng and pr event s t he
br i dge f r omf al l i ng out of
pl ace whi l e heat i ng. ( See
St ep VI - 19)
3- 100
The chai nst ay br i dge i s t he
next i t emt o be si l ver
br azed on. Her e agai n, a
FI G #148 ver y snug f i t wi t h a
mi ni mum of gaps i s
necessar y. Agai n t he dummy
wheel i s used t o f i nd t he
l ocat i on of t he br i dge.
( See St ep VI - 31)
Af t er t he br i dges ar e i n
pl ace, t he dr opout
al i gnment can be checked
FI G #149wi t h t he
"
H
"
t ool s. Make
sur e t he "H" t ool s ar e
t i ght bef or e usi ng t hemt o
bend t he dr opout s. I f t he
dr opout s pul l ed t oget her
due t o gaps or sl oppy f i t ,
t he r ear end must be spr ead
or t he br i dges must be
r ei nst al l ed. ( See St ep
VI - 34)
When i nst al l i ng wat er
bot t l e bosses, l ook out f or
sever al f act or s; 1- Get t he
FI G #150 hol es t he cor r ect di st ance
apar t . 2- Don' t mount t wo
bot t l es t oo cl ose t oget her .
3- Don
'
t mount a seat t ube
bot t l e t oo hi gh or t oo
cl ose t o t he der ai l l eur .
4- Mount under si de bot t l es
as cl ose as possi bl e t o t he
bot t ombr acket . ( See St ep
VI - 35)
3- 101
Wat er bot t l es ar e, by al l
st andar ds, t he easi est
br aze- ons t o i nst al l . The
FI G #151 per sonal r ecor d f or t he
aut hor i s 7 set s i n one
hour on a t andemf r ame. Be
car ef ul not t o get si l ver
i n t he t hr eaded hol e. ( See
St ep VI - 35)
The easi est way t o l ocat e
t op t ube cabl e gui des i s t o
pl ace t he f or e and af t ones
FI G #152 5cmf r omt he poi nt s of t he
l ugs. Then spl i t t he
di st ance bet ween t hose t wo
f or t he l ocat i on of t he
mi ddl e one. ( See St ep
VI - 35)
Fi r st a t i ny dab of si l ver
FI G #153 i s appl i ed t o t he l ocat i on
wher e t he gui de wi l l be
i nst al l ed. ( See St ep
VI - 35)
3- 102
Hol d t he gui de wi t h a pai r
of wor n out pl i er s as t he
heat i ng and cool i ng wi l l
FI G #154 r ui n a good pai r . Gent l y
pr eheat t he f l uxed br aze-
on. Hol d i t i n pl ace on
t he t ube and r emel t t he
si l ver . I f done pr oper l y,
t he br aze- on wi l l nest l e
i nt o pl ace. Af t er appl yi ng,
si ght down t he t op of t he
t ube wi t h one eye cl osed t o
check f or al i gnment . ( See
St ep VI - 35)
Lever bosses can be appl i ed
i n t he same manner . Gr eat
car e must be t aken t o get
FI G #155 t hese al i gned i n bot h
pl anes. J i gs can be made
t o make i nst al l at i on of
br aze- ons a gr eat deal
easi er f or t he begi nner .
However , wi t h exper i ence,
t he bui l der becomes f ar
mor e agi l e at handl i ng
t hese smal l pi eces. ( See
St ep VI - 35)
Bef or e i nst al l i ng bot t om
br acket cabl e gui des, a
smal l bead of si l ver shoul d
FI G #156 be l ai d ar ound t he
per i met er s of t he t ubes
wher e t hey pr ot r ude i nt o
t he bot t ombr acket shel l .
Thi s wi l l i nsur e a mor e
sol i d j oi nt . ( See St ep
VI - 36)
3- 103
Her e t he l ef t si de bot t om
br acket cabl e gui de i s
bei ng pr eheat ed f or
FI G #157 i nst al l at i on. The pl i er s
make an excel l ent heat si nc
t o keep t he pi ece f r om
get t i ng t oo hot . Al ways
hol d t he br aze- ons wi t h t he
pl i er s whi l e appl yi ng heat .
( See St ep VI - 35 & 36)
Her e t he bot t ombr acket
gui de i s bei ng i nst al l ed.
Make sur e t o get a good
FI G #158 f i l mof si l ver under t hi s
one as i t const ant l y has
upwar d pr essur e bei ng
exer t ed on i t dur i ng
r i di ng. ( See St ep VI - 35 &
36)
Her e t he r i ght si de bot t om
br acket cabl e gui de i s
bei ng i nst al l ed. The
FI G #159bot t ombr acket cabl e gui des
shoul d be i nst al l ed so t hat
t he shi f t cabl es ent er t he
br aze- ons bel ow t he cent er
l i ne of t he down t ube.
Not e how t he l ef t br aze- on
has been bent i nwar d at t he
back. ( See St ep VI - 35 & 36)
3- 104
Af t er cl eani ng t he f l ux and
oxi dat i on away f r om t he
bot t ombr acket ar ea, t he
FI G #160 t hr eads must be cl eaned out
wi t h bot t ombr acket l i ne
t aps. NEVER r un t aps
t hr ough t hr eads t hat st i l l
have f l ux i n t hem. ( See
St ep VI - 38)
The bot t ombr acket must be
FI G #161 f aced agai n. Be car ef ul
not t o t ake t oo heavy of a
cut and go under si zed.
( See St ep VI - 39)
Al l f r ames shoul d have a
ser i al number . Not onl y i s
i t necessar y f or
FI G #162 i dent i f i cat i on i n case of
t hef t , but i t can al so be
used t o t el l when t he f r ame
was bui l t , who bui l t i t ,
how many have been bui l t
et c. Not e t he r i gi d
cl ampi ng necessar y t o st amp
number s. See how a bot t om
br acket cup pr event s
di st or t i on of t he shel l
dur i ng st ampi ng. ( See St ep
VI - 40)
3- 105
A dupl i cat e ser i al number
on t he st eer i ng col umn i s a
FI G #163 good i dea. Thi s spot i s
hi dden f r omvi ew and may be
over l ooked by a woul d be
t hi ef . ( See St ep VI - 41)
Her e i s t he compl et ed f r ame
r eady f or pai nt i ng. I f
t her e wi l l be a l engt hy
FI G #164 wai t f or t he pai nt j ob, t he
f r ame and f or k shoul d be
scr ubbed and f l ushed wi t h
Dupont 5717S met al pr ep t o
pr event r ust i ng. Use heavy
r ubber gl oves whi l e
handl i ng 5717S1 Avoi d
br eat hi ng t he f umes al so.
( See St ep VI - 42)
3- 106
FRAMEBUI LDER' S LABOR AND PRI CE SCHEDULE
Thi s f r amebui l der ' s l abor / pr i ce manual i s desi gned f or
t he bui l der who has bui l t at l east 10 successf ul f r ames
and want s t o cont i nue on a smal l scal e. I n set t i ng up
t hi s pr i ce schedul e i t was t aken i nt o consi der at i on
t hat most of t hose usi ng i t woul d be wor ki ng out of
t hei r gar age or basement and t hei r over head cost s ar e
bur i ed wi t hi n t hei r home/ l i vi ng expenses. I f t hi s i s
not t he case wi t h you, an "our pr i ce
"
col umn i s gi ven
t o al l ow a gr eat er mar gi n of pr of i t . I t i s not hi ghl y
r ecommended t o go bel ow t he pr i ces t oo much as t he l ow
pr of i t mar gi n woul d be pr ohi bi t i ve.
I n choosi ng t he r epai r s t o be l i st ed t he f ol l owi ng
f act or s have been consi der ed; you have a good suppl i er
of br aze- ons, you do your own pai nt i ng or have a
r el i abl e sour ce t o do i t f or you, you have a sol i d
wor kbench wi t h a f i r ml y anchor ed vi se mount ed on i t ,
you have a r epai r st and, you own an oxy- acet el yne
t or ch, you have a smal l compr essor , you have an
adequat e sel ect i on of hand t ool s, f i l es, dr i l l and
gr i ndi ng wheel , you own a mechani cs' t ool case
( Campagnol o, Zeus, Gi ppi emi , VAR or Bi cycl e Resear ch
wi l l do) and have put some amount of t i me i nt o maki ng
some usabl e f r amebui l di ng f i xt ur es. I f you f al l shor t
of t hese r equi r ement s, you wi l l have pr obl ems when you
i nvi t e pot ent i al cust omer s over f or your ser vi ces as
your capabi l i t i es wi l l f al l shor t of t hi s manual . I f ,
on t he ot her hand, you ar e f ar bet t er equi pped t han t he
above r equi r ement s cal l f or , you may want t o pur chase a
copy of t he PATEREK cat al ogue and use t hat as your own
manual .
Her e ar e some wor ds of caut i on f or t he begi nni ng
f r amebui l der ; don' t accept f ul l payment f or a j ob t i l l
i t i s compl et ed, don' t pr omi se t o get an i t emyou ar e
not sur e wher e t o obt ai n, don' t l et a j ob out t he door
t i l l i t i s f ul l y pai d f or , guar ant ee your wor k- - and
don' t do any wor k whi ch you f eel you coul d not
guar ant ee. Fi nal l y, don' t do a j ob on a "l ow bi d. "
Ther e ar e t wo pages i n t hi s manual whi ch you have
per mi ssi on t o make copi es of i n a l i mi t ed manner . They
ar e t he Fr ameset Or der For mand t he Component Sheet .
4- 1
BRAZE- ON PRI CE LI ST
Sugg. Our
Pr i ce Pr i ce
1. Wat er Bot t l e Mount s
A. Pl ai n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $ 9. 00
B. Scal l oped Di amond St i f f ener s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
C. Pl ai n Di amond St i f f ener s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
2. Br azed on Fr ont Der ai l l eur ( i ncl udes Der ai l l eur )
A. Campagnol o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44. 95
B. Shi mano Dur a Ace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34. 95
3. Shi f t Lever Bosses
A. Campagnol o ( Fi t s Campy, Si mpl i x S. L. J . , Ri no, Sunt our ) . . . 12. 50
B. Modi f i ed Campagnol o ( al l ows f or use of Bar cons) . . . . . . . . . . . . . 18. 50
C. Shi mano . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12. 50
4. Cant i l ever Br ake set s ( speci f y r egul ar , t andemor mount ai n use)
Lever s and cabl es not i ncl uded
A. Maf ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44. 95
B. Di a Compe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44. 95
C. Shi mano . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44. 95
5. Rear Rack Fi t t i ngs
A. I nt er nal ( usi ng wat er bot t l e boss) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
B. Ext er nal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
6. Low Ri der Mount s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
7. Top Tube Cabl e Gui des
A. 2 Cl ose Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
B. 2 Di st ant Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
C. 1 Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
8. Cabl e St op ( 3. 50 i f done wi t h 2 ot her i t ems)
A. Shi mano . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
B. Campagnol o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
C. Spl i t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
D. Heavy Dut y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
9. Pump Peg ( 3. 50 i f done wi t h 2 ot her i t ems) - Speci f y br and and
l engt h and whi ch f r ame t ube t o be i nst al l ed on.
A. St andar d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
1/ 4" bal l bear i ng t o mount Si l ca f r ame- f i t under t op t ube . 5. 00
10. Cl amp st op ( 3. 50 i f done wi t h 2 ot her i t ems) . . . . . . . . . . . . . . . . . . . . . . 5. 00. . .
- -
11. Chai n Hanger ( 3. 50 i f done wi t h 2 ot her i t ems) . . . . . . . . . . . . . . . . . . . . 5. 00
12. Bot t omBr acket Gui des
A. Campagnol o ( t op si de) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. 00
B. Shi mano ( t op si de) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. 00
C. Ci nel l i ( t op si de) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. 00
D. Under Si de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. 00
13. Bar con st ops - Speci f y st yl e t o be used ( see #8) . . . . . . . . . . . . . . . . . . 7. 50
14. Ext r a Eyel et s f ar f ender s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 50. pr
15. Br ake br i dge r ei nf or ci ng sl eeve
A. St andar d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
E. Al l en Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0. 00
16. Spoke Car r i er / Chai nst ay Guar d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. 50
17. Cent er Pul l Hanger
A. Si mpl e Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
B. Tr i angul ar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18. 00
4- 2
PAI NTI NG PRI CE LI ST
Sugg. Our
Pr i c e Pr i c e
Over haul f or pai nt i ng; i nc l udes r epac ki ng bot t om br ac ket & head and
r emovi ng & r epl ac i ng al l c omponent s . ( Repac ki ng of hubs and c l eani ng
up t he dr i ve t r ai n i s ext r a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $45. 00
St r i ppi ng ol d pai nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. 00
Mas ki ng c hr ome:
Seat s t ays , c hai ns t ays , and f or k bl ades . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
Head l ugs and/ or c r own . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
Si ngl e c ol or pai nt j ob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60. 00
Two t one pai nt j ob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90. 00
Dec al wor k ( mi ni mum c har ge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10. 00
Pi ns t r i pi ng ( mi ni mum c har ge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. 00
Cl ear c oat ( mus t go over t he t op of dec al s and pi ns t r i pi ng . . . . . . . . . . 10. 00
FRAME REPAI R PRI CE LI ST
BOTTOM BRACKET:
Cl ean out or s t r ai ght en out t hr eads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 50
Fac e mi l l i ng ( l i ght c ut ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 50
Fac e mi l l i ng f r om 70mm t o 68mm ( heavy c ut ) . . . . . . . . . . . . . . . . . . . 12. 50
Fi l l damaged t hr eads wi t h br as s and r et ap t o or i gi nal s pec s . . . . 25. 00
Rei ns er t and r ebr az e an exi s t i ng f r ame t ube whi c h has pul l ed out of
t he bot t om br ac ket s hel l :
Si l ver br az ed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20. 00
Br as s br az ed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. 00
HEAD:
Mi l l t op and bot t om of head t ube ( wi t hout r eami ng) . . . . . . . . . . . . . . . 8. 00
Mi l l and r eam t op and bot t om of head t ube ( l i ght c ut ) . . . . . . . . . . . 10. 00
Mi l l head t ube s hor t er t o gai n mor e t hr eads on t he s t eer i ng c ol umn
( heavy c ut ) mi ni mum c har ge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. 00
FORK:
Al i gn f or k t i ps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 50
Reat t ac h dr opout ( s end ol d dr opout al ong wi t h f or k) . . . . . . . . . . . . . . . 7. 00
Repl ac e dr opout s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25. 00
Repl ac e Bl ades :
Br i t i s h c r os s s ec t i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40. 00
Cont i nent al oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50. 00
Mi l l f or f or k c r own r ac e ( l i ght c ut ) 26. 4mm. . . . . . . . . . . . . . . . . . . . . . 4. 50
Mi l l f or f or k c r own r ac e t o gai n 1 or 2 t hr eads on t he s t eer i ng
c ol umn ( heavy c ut ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. 00
4- 3
FRAME REPAIRLIST ( c ont i nued)
Sugg. Our
Pr i c e Pr i c e
Tap s t eer i ng c ol umn t o f i t s mal l er f r ame:
Fi r s t c ent i met er . 3. 00
Eac h addi t i onal c ent i met er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Fi l l damaged t hr eads wi t h br as s and r et ap t o or i gi nal s pec s . . . . 15. 00
REARTRIANGLE:
Repl ac e dr opout s ( Camoy NR) - eac h . . . . . . . . . . . . . . . . . . . . . . . . . $40. 00
pai r 60. 00
Repl ac e c hai ns t ays ( REY 531) - eac h . . . . . . . . . . . . . . . . . . . . . . . . . . . 50. 00
pai r . . . 75. 00
Repl ac ement of c hai ns t ays i nc l udes a br i dge and c abl e s t op.
Repl ac e s eat s t ays ( REY 531) - eac h . . . . . . . . . . . . . . . . . . . . . . . . . . . 40. 00
- pai r . . . 65. 00
Repl ac ement of s eat s t ays i nc l udes a br ake br i dge.
Repl ac e or r el oc at e br ake br i dge - St andar d t ype . . . . . . . . . . . . . . . . . 15. 00
- Al l en s t yl e wi t h s t i f f ener s . . 25. 00
St r ai ght en s eat s t ay wi t h no ki nk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
St r ai ght en s eat s t ay and f i l l & s moot h out ki nk . . . . . . . . . . . . . . . . 25. 00
Fi l l der ai l l eur hanger t hr eads wi t h br as s and r et ap . . . . . . . . . . . . . . 15. 00
Cl ean out c hai n adj us t er t hr eads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
Al i gn t i ps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 50
Al i gn der ai l l eur han
g
er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. 50
Open r ear t r i angl e t o ac c ommodat e a 6 s peed
Col d bend ( not hi ghl y r ec ommended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 00
I ns t al l l onger br ake br i dge- - s ee above
FRONT TRI ANGLE:
Repl ac e head t ube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75. 00
Repl ac e down t ube and bot t om head l ug . . . . . . . . . . . . . . . . . . . . . . . . . 150. 00
Repl ac e t op t ube and t op head l ug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150. 00
Repl ac e bot t om br ac ket s hel l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150. 00
Repl ac e down t ube, head t ube and t op t ube . . . . . . . . . . . . . . . . . . . . . 250. 00
Spl i c e a c r ac ked f r ame t ube bac k t oget her . . . . . . . . . . . . . . . . . . . . . 25. 00
DRESSI NG A FRAME:
Si nc e many new f ac t or y f r ames ar e not c l eaned up ver y wel l at t he
f ac t or y, t he deal er mus t s ee t o i t t hat t he bot t om br ac ket i s
t apped and f ac ed, t he head t ube i s mi l l ed and r eamed, t he f or k
c r own i s mi l l ed, t he s eat t ube i s r eamed f or a pr oper f i t , t he
t i ps ar e al i gned, and s mal l t hr eaded hol es ar e c l eaned out .
( Thi s s houl d al s o be done af t er a pai nt j ob) . . . . . . . . . . . . . . . . . . . . 25. 00
CUSTOMFRAMEPRICELIST
LEVEL-1:
Thes e ar e avai l abl e as t our i ng, s por t / t our i ng, or r ac i ng f r ames .
Mat er i al s us ed f or l evel - 1 f r ames c ons i s t of . 6mm/ . 9mm doubl e
but t ed f r ame t ube s et s , s t amped l ugs , medi um qual i t y bot t om
br ac ket s hel l and, s t andar d r oad dr opout s . Br az e- ons i nc l ude
one wat er bot t l e mount , bot t om br ac ket gui des , t op t ube gui des ,
c hai ns t ay s t op, and c hai nhanger . A pol yur et hane f i ni s h i s t hen
appl i ed. Dec al s ar e opt i onal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400. 00
4- 4
CUSTOM FRAME PRI CE LI ST ( c ont i nued)
Sugg. Our
Pr i c e Pr i c e
LEVEL- 2s
Thes e ar e avai l abl e as t our i ng, s por t / t our i ng, or r ac i ng f r ames .
Mat er i al s us ed f ar l evel - 2 f r ames c ons i s t of . 8mm/ . 9mm or . 6mm/
. 8mm ( 5L) doubl e but t ed f r ame t ube s et s , i nves t ment c as t l ugs -
f or k c r own- bot t om br ac ket and, hi gh qual i t y dr opout s . Br az e- ens
i nc l ude t wo wat er bot t l e mount s , bot t om br ac ket gui des , t op t ube
gui des , c hai ns t ay s t op, c hai n hanger , pump peg, l ever bos s es or
Bar c on s t ops and, al i en bol t br i dges . A pol yur et hane f i ni s h
i s t hen appl i ed. Dr y t r ans f er dec al s ar e opt i onal . A f i nal
pol yur et hane c l ear c oat i s t hen appl i ed . . . . . . . . . . . . . . . . . . . . . 500. 00
SIZEANDWEIGHT RECOMMENDATIONS
Regul ar doubl e but t ed t ubi ng s et s c an us ual l y be bui l t as t al l as 64c m and s houl d not
be r i dden by a r i der over 225 l bs .
SL doubl e but ed t ubi ng s et s c an us ual l y be bui l t no bi gger t han 61c m and s houl d not
be r i dden by a r i der over 160 l bs .
Ul t r a- l i ght doubl e but t ed t ubi ng s et s c an us ual l y be bui l t no bi gger t han 58c m and
s houl d not be r i dden by a r i der over 150 l bs . f or t i me t r i al i ng or 125 l bs . f or
gener al r ac i ng.
For ver y t al l r i der s t he Reynol ds " Tal l Set
"
i s avai l abl e and c an be bui l t as t al l as
76c m. Thi s woul d add about $50. 00 t o t he c os t of t he f r ames et .
For r i der s bet ween 160 and 195 l bs . who want t o r i de SL, t he down t ube and c hai ns t ays
c an be r epl ac ed wi t h t he next heavi er gage t ubi ng. Thi s woul d add about $35. 00 t o
t he c os t of t he f r ames et .
4- 5
Today' s Dat e
FRAMESET ORDER FORM/ SPEC SHEET Tar get Dat e
Name - NOTES-
Addr es s
Phone
Hei ght Wei ght
I ns eam Ar m Lengt h
Cubi t Lengt h
Fr ame Type
GEOMETRI C SPECS:
Seat t ube l engt h
Top t ube l engt h
Fr ont c ent er
Chai ns t ay l engt h
Seat t ube angl e
Head t ube angl e
Bot t om br ac ket dr op
For k r ake
Es t i mat ed t r ai l
Br i dge c l ear anc e
Cr own/ t i r e c l ear anc e
Rear hub wi dt h
Ti r e s i z e
BRAZE- ONS: add $ MATERI ALS SPECS:
L. H. BB gui de Tubi ng
R. H. BB gui de Lugs
Chai ns t ay s t op Bot t om br ac ket
W. B. #1 For k c r own
W. B. #2 Dr op out s
W. B. #3 Pai nt
W. B. #4 Br az i ng Mat er i al
Top t ube s t ops
Top t ube gui des COST OF FRAMESET:
Lever bos s es
Bar c on s t ops Bas e pr i c e of f r ame $
Pump peg
Rear r ac k mount s Ext r a br az e- ons
Low r i der mount s
Spoke c ar r i er Spec i al r eques t s
Cant i l ever s
Cut - out s Subt ot al
Headc r es t
Ot her Tax
Tot al
Downpayment
Br az e- on t ot al
Bal anc e Due
4- 6
COMPONENT SHEET/ ORDER BLANK Dat e
Es t . Del i ver y Dat e
DESCRI PTI ON
Dr i ve Tr ai n:
Cr anks
BB
Chai nr i ngs
Pedal s
Toe c l i ps
Toe s t r aps
Chai n
Fr eewheel
Wheel s :
Hubs
Spokes
Ri ms
Ri ms t r i ps
Tubes
Ti r es
Shi f t i ng s ys t em:
Fr . der ai l l eur
R. der ai l l eur
Lever s
Cabl es
Cl amps
Br ake s ys t em:
Runni ng gear :
Heads et - -
Seat pos t
Saddl e
Bar s
St em
Bar Wr ap __
Pl ugs
Pi nc h bol t
Ac c es s or i es :
Pump
Car r i er
Li ght s
Bc t t l e r ac k
Bot t l e
Speedo
Loc k
Ot her :
Name
Addr es s
Phone _
Bi ke Type
Component Gr oup Tot al
Tax
Tot al
Down Payment
Bal anc e Due
4- 7
FI XTURES
Ther e ar e many i t ems necessar y f or f r ame bui l di ng
t hat ar e not gener al l y avai l abl e on t he open mar ket .
These t hi ngs must ei t her be made f or t he bui l der by a
machi ne shop or must be made by t he f r amebui l der . To
si mpl i f y mat t er s, any of t hese i t ems whi ch must be
speci f i cal l y made f or t he bui l der wi l l be r ef er r ed t o
as
"
f i xt ur es" f r omnow on.
Fi xt ur es can be di vi ded i nt o t hr ee mai n cat egor i es:
1 - Measur i ng f i xt ur es
2 - Hol di ng f i xt ur es
3 - Bendi ng f i xt ur es
Each of t he j i gs i n t he t hr ee mai n cat egor i es wi l l
be di scussed and di agr ams wi l l be used t o show t he
f i xt ur es i n det ai l .
Aset of det ai l ed pl ans f or t he f ol l owi ng f i xt ur es
ar e avai l abl e on r equest f r omt he aut hor at a cost of
$10. 00. Send t o THE FRAMEBUILDER'S GUILD, RT. 2,
BOX 234, RIVER FALLS, WISCONSIN 54022
MEASURI NG FI XTURES
DUMMY HEADSET
The dummy headset i s made up of t wo bushi ngs. When
assembl ed on t he st eer i ng col umn, t hey r epr esent t he
act ual st ack hei ght of a r eal headset . The smal l
bushi ng i s t he bot t ompar t of t he headset and t he
l ar ger bushi ng i s t he t op par t of t he headset . The
smal l er bushi ng i s dr opped ont o t he st eer i ng col umn.
The head t ube of t he f r ame i s t hen l ower ed ont o t he
st eer i ng col umn unt i l i t r est s on t he bushi ng. Then
t he l ar ger bushi ng dr ops ont o t he st eer i ng col umn and
snugs up agai nst t he head t ube. The l ar ger bushi ng has
a set scr ew i n t he si de whi ch, when t i ght ened down,
wi l l hol d t he f or k and f r ame t oget her . The dummy
headset has f our i mpor t ant f unct i ons:
1 - I t measur es t he l engt h at whi ch t o cut t he
st eer i ng col umn. Scr i be t he mar k f or t he cut
at t he ver y t op of t he dummy headset .
2 - I t hol ds t he f or k cr own and t he bot t omof t he
head t ube t he cor r ect di st ance apar t whi l e t he
r ear end j i g i s bei ng used.
3 - I t al l ows t he qui ck and easy assembl y of t he
f r ameset f or i nspect i on pur poses.
4 - I t can be usef ul i n st or age and t r anspor t at i on
of t he f r ameset .
5- 1
DUMMY REAR WHEEL
The dummy r ear wheel i s a t r i angul ar - shaped devi ce
t hat act s as a r ear wheel whi l e t he br i dges ar e bei ng
i nst al l ed i n t he r ear t r i angl e. Use of t he dummy r ear
wheel l essens t he r i sk of r ui ni ng t he hub par t s or t i r e
on a set of f r amebui l der ' s wheel s dur i ng br azi ng. A
pr oper l y const r uct ed dummy r ear wheel has f our
f unct i ons i n f r ame bui l di ng:
1
- The t i p of t he t r i angl e on t he dummy r ear wheel
r epr esent s t he out er di amet er of t he t i r e.
When scr ewed i n, i t
'
s set f or 700c. When
scr ewed out , i t ' s set f or 27".
- The smal l mar ks t hat appear about 2 or 3
cent i met er s f r omt he end show wher e on t he r i m
t he br ake shoes shoul d hi t . The upper mar k i s
f or 27" and t he l ower mar k i s f or 700c.
- The di st ance bet ween t he l ocknut s can be set
f or f i ve speed ( 120mm) or si x speed ( 125mm) .
Thi s wi l l hol d t he dr opout s t he cor r ect
di st ance apar t whi l e si l ver br azi ng t he br i dges
i n pl ace.
- The dummy wi l l show i f ei t her st ay i s l onger by
bei ng of f cent er bet ween t he seat st ays i f a
pr obl emexi st s.
BOT
T
OM

BRACKET M IC
R
O M ETER
.
DUMMY BRAKE
The dummy br ake i s an upsi de- down, u- shaped, f l at
pi ece of sheet st ock t hat si mul at es t he br ake whi l e
cut t i ng f or k bl ades. Usi ng t he dummy br ake i s qui cker
and si mpl er t han i nst al l i ng an act ual br ake cal i per
dur i ng t hi s oper at i on. The dummy br ake has one mai n
f unct i on- - i t shows what t he di st ance shoul d be bet ween
t he br ake cent er bol t and t he mi ddl e adj ust ment f or t he
br ake shoes. The mar ks at t wo l evel s wi l l gi ve t hi s
di st ance f or bot h shor t r each and r egul ar r each
Campagnol o br akes. The dummy br ake shoul d be used i n
conj unct i on wi t h a set of f r amebui l der ' s wheel s.
DUMMY
BRAKE.
BOTTOMBRACKET MI CROMETER
The bot t ombr acket mi cr omet er ( B. B. Mi ke f or shor t )
i s used t o measur e t he amount of def l ect i on t hat has
occur r ed i n t he down or seat t ubes as t hey l eave t he
bot t ombr acket shel l . I t i s used i n a f ashi on si mi l ar
t o a wheel di shi ng t ool i n t hat i t i s l ai d al ong t he
f aces of a cl eanl y- f aced bot t ombr acket shel l . A
r eadi ng i s t aken out at t he mi cr omet er head. I t i s
t hen f l i pped ar ound t o t he opposi t e f ace of t he shel l
and anot her r eadi ng i s t aken. The amount of def l ect i on
t hat has occur r ed i s hal f of t he di f f er ence bet ween t he
t wo r eadi ngs. The B. B. Mi ke can be consi der ed t o be
t he poor man' s sur f ace t abl e. I f i t i s made out of
hi gh qual i t y mat er i al s, i t i s ext r emel y accur at e.
5-3
FRAME DESI GNER' S STRAI GHT EDGE
To make t he desi gni ng and dr awi ng of t he wor ki ng
dr awi ng f ast er and easi er , a speci al st r ai ght edge can
be used. I t i s exact l y 1 1/ 8" wi de and can be l ai d on
t he dr awi ng exact l y wher e t he seat or down t ubes ar e t o
be dr awn i n pl ace. Dr awi ng t he t ubes can t hen be done
qui ckl y by scr i bi ng bot h si des of t he t ubes on each
si de of t he st r ai ght edge. One end of t he st r ai ght
edge has a not ch i n t he exact cent er . Thi s not ch hel ps
l ocat e wher e t he down t ube goes t hr ough t he cent er of
t he bot t ombr acket shel l .
FRAME. DESIGNERS S T
R
A
I
GHT
.
EDGE ( 30
"
X 1 1/ 8" X 1/ 4")
FORK TWI ST I NDI CATOR
When t he f or k i s j i gged up i n t he f or k j i g, t he
f or k t wi st i ndi cat or can be l ai d acr oss t he upper par t
of t he f or k bl ades. A r eadi ng i s t hen t aken t o f i nd
t he di st ance bet ween t he i ndi cat or and t he sur f ace of
t he f or k j i g. The i ndi cat or i s t hen f l i p- f l opped and
anot her r eadi ng i s t aken on t he opposi t e si de. I f t he
r eadi ngs ar e di f f er ent , t he cr own must be t wi st ed t o
compensat e f or t he di f f er ence. Thi s i s done t i l l t her e
i s no di f f er ence bet ween t he t wo r eadi ngs.
FORK TWIST INDICATOR.
HOLDI NG FI XTURES
TUBI NG CLAMPS OR FAMEBUI LDER
'
S BLOCKS
Cl ampi ng t hi nwal l t ubi ng i n a vi se can be r at her
r i sky busi ness. The si des of t he t ube can be f l at t ened
and t he t ube consequent l y r ui ned. To el i mi nat e t he
r i sk of t hi s pr obl em, a set of bl ocks can be f ashi oned
t o mat ch t he di amet er of t he t ubes. When t he t ubes ar e
cl amped i n such a set of bl ocks, t her e i s no r i sk of
f l at t eni ng t he t ube. The bl ocks can be made of
al umi numby a machi ne shop or even homemade out of
har dwood.
5- 4
TUBING CLAMPS
REAR END J I G
The r ear end j i g i s used t o hol d t he f r ont
t r i angl e, dummy headset , and f or k i n pl ace whi l e t he
r ear t r i angl e i s const r uct ed. The j i g i s made up of
si x mai n par t s:
A - The seat t ube cl amp assembl y ( 8, 9& 11)
B - The st ay r est ( 6 & 7)
C - The angl e bar ( 10)
D - Rear axl e post assembl y ( 3, 4 & 5)
E - Fr ont axl e post assembl y ( 1, 3 & 4)
F - Base.
Thi s i s a ver y expensi ve f i xt ur e and no expense
shoul d be spar ed i n t he pr oduct i on of t hi s f i xt ur e. By
al l means, i t must be st r ai ght and t r ue.
R AR O} !C
5- 5
SOFT JAWS
MODI FI ED BAR CLAMP
A r egul ar f ur ni t ur e cl amp can be t aken and modi f i ed
i n such a way t hat i t wi l l cl amp t he head and seat
t ubes and pul l t hemt owar d each ot her . Thi s must be
done so t hat t he ends of t he t op t ube come i nt o cont act
wi t h t he back si de of t he head t ube and t he f r ont si de
of t he seat t ube. Thi s i s necessar y whi l e si l ver
br azi ng t he seat l ug and t op head l ug i n pl ace.
SOFT J AWS FOR THE VI SE
A pai r of sof t j aws can be f ashi oned out of 1/ 8"
t hi ck br ass or al umi numsheet . Si mpl y cut t wo pi eces
of t he mat er i al t o t he same wi dt h as t he j aws of t he
vi se by about t hr ee i nches. Cl amp one pi ece i n t he
vi se so i t ' s st i cki ng about 1 1/ 2" st r ai ght up i n t he
ai r . Take a bi g hammer and bend t he pi ece over t o
conf or mt o t he shape of t he t op of t he vi se. Do t he
same wi t h t he ot her pi ece. These sof t j aws can now be
used t o cl amp a var i et y of pi eces i n t he vi se wi t hout
damagi ng t hemwi t h t he t eet h i n t he r egul ar vi se j aws.
5- 6
FORK J I G
The f or k j i g i s desi gned t o hol d t he bl ade/ dr opout
and cr own/ col umn pi eces i n pl ace whi l e si l ver br azi ng
t he bl ades t o t he cr own. The f or k j i g can be br oken
down i nt o t hr ee mai n par t s:
1 - The t abl e ( A)
2 - The st eer i ng col umn cl amp ( C)
3 - The r ake adj ust ment assembl y ( B, D, E)
Thi s f i xt ur e i s a ver y expensi ve pi ece t o pr oduce
and shoul d def i ni t el y be made st r ai ght and t r ue.
MODI FI ED C- CLAMP ( #1)
When si l ver br azi ng t he t op t ube i nt o pl ace, car e
must be t aken so t hat t he seat l ug doesn
'
t cr eep upwar d
and t he t op head l ug doesn' t cr eep downwar d. To
pr event t hi s, modi f i ed C- cl amps can be used t o cl amp
t hose t wo l ugs t o t he t ubes. The r ounded anvi l on t he
C- cl amp wi l l pr event t he t ube and l ug f r omdef or mi ng
under heat and pr essur e.
5- 7
MODI FI ED C- CLAMP ( #2)
When si l ver br azi ng any of t he l ugs, somet i mes t he
poi nt s st i ck up and do not l i e f l at agai nst t he t ube.
I f t hi s i s t he case, a modi f i ed C- cl amp can be used t o
hol d t he poi nt s of t he l ug down.
BOTTOMBRACKET J I G
When si l ver br azi ng t he down t ube or seat t ube i nt o
t he bot t ombr acket shel l , t he pi eces must be hel d i n
pl ace. The B. B. j i g cl amps t he bot t ombr acket shel l
and ei t her t he down or seat t ube. The B. B. J i g al so
makes sur e t hat t he shel l and t ube cent er l i nes ar e
per pendi cul ar t o each ot her .
5- 8
HEAD TUBE STABI LI ZER ARM
The head t ube st abi l i zer ar mi s an opt i onal devi ce
t hat makes sur e t he head t ube and seat t ube ar e i n t he
same pl ane whi l e down t ube i s si l ver br azed i nt o t he
bot t ombr acket shel l .
BENDI NG FI XTURES
DOWN TUBE PROTECTOR SHEATH
The down t ube pr ot ect or sheat h i s a pi ece of 1 1/ 4"
t ubi ng t hat i s spl i t up t he mi ddl e al ong t he ent i r e
l engt h. I t can be put ar ound t he down t ube bef or e col d
set t i ng t he j oi nt comi ng out of t he bot t ombr acket
shel l . Usi ng t he sheat h gr eat l y r educes t he r i sk of
cr i mpi ng t he down t ube dur i ng col d set t i ng.
5- 9
1 1/ 8" STEEL BAR
A 1 1/ 8
"
di amet er st eel bar 1 met er l ong shoul d be
kept on hand. I t i s an excel l ent r ei nf or cement t o
sl i de i nsi de t he head t ube dur i ng col d set t i ng of t he
bot t om head j oi nt . I t al so comes i n handy f or
l ever age.
1" STEEL BAR
A 1" di amet er st eel bar shoul d be kept on hand. I t
i s an excel l ent r ei nf or cement t o sl i de i nsi de t he seat
and down t ubes dur i ng col d set t i ng. I t al so comes i n
handy f or l ever age.
REAR TRI ANGLE PERSUADER
Thi s f i xt ur e i s handy f or movi ng t he r ear t r i angl e
t o t he l ef t or r i ght at t he t i me t he br i dges ar e r eady
t o be i nst al l ed. I t gi ves a t r emendous amount of
l ever age i n doi ng t hi s col d set t i ng pr ocedur e.
5- 10
FORK BLADE BENDER
The f or k bl ade bender wi l l bend f or k bl ades t o t he
cor r ect r adi us wi t hout maki ng unsi ght l y cr i mps.
Al umi numi s t he best mat er i al f or t hi s f i xt ur e. I t i s
a cost l y f i xt ur e but , hal f a dozen r ui ned f or k bl ades
ar e qui t e cost l y al so.
5- 11
Fr ame and f or k bui l di ng f i xt ur es ar e avai l abl e f r omAndr ew Hague i n
Gr eat Br i t ai n. These f i xt ur es ar e f ul l y compat abl e wi t h t he PATEREK
met hod of f r amebui l di ng wi t h mi nor al t er at i ons t o t he pr ocedur e out -
l i ned i n t he CHECKLI ST sect i on of t hi s book. These f i xt ur es can be
pur chased f r omPhi l Wood ( see t he r esour ce sect i on at t he end of t he
book. ) or can be or der ed di r ect l y f r omAndr ew Hague ( See t he r esour ce
sect i on at t he end of t he book. ) .
- Adjusts to any angle and size of frame
- Specify whethen for imperial or metric size tubes.
- Made for 68mm, long bottom bracket shells.
- The tube supports also serve as heat sinks to
protect the tube when brazing in the jig.
- With this jig you can make a lugless frame as
easily as a lugged frame,
- Can be used on a bench or suspended from the
ceiling.
- Easily dismantled for storage.
All steel construction in bare metal finish.
- The fork jig can be supplied separately if required.
5-12
TOOLS
Tool s ar e di f f er ent f r omf i xt ur es i n t hat t hey can
be r eadi l y pur chased f r omsuppl i er s. Of cour se t her e
ar e l i t er al l y t housands of di f f er ent t ool s t hat ar e
par t i cul ar l y necessar y f or f r amebui l di ng. The
f ol l owi ng pages will di scuss t ool s t hat ar e necessar y
f or f r amebui l di ng wi t h par t i cul ar at t ent i on pai d t o
t hose t hat ar e f avor i t es of t he aut hor .
MECHANI CS TOOL CASE
The mechani c
'
s t ool case has wi t hi n i t al l t he
t ool s necessar y t o t ap & mi l l bot t ombr acket s, mi l l &
r eamhead t ubes, al i gn f or k dr opout s, t ap st eer i ng
col umns, and mi l l f or k cr own r ace seat s. These t ool s
ar e absol ut el y essent i al t o bui l di ng qual i t y f r ameset s.
I f i t i s not possi bl e t o own a mechani c' s t ool case, at
l east ar r ange f or anot her bui l der t o do any necessar y
t appi ng, mi l l i ng, and r eami ng.
Sever al compani es manuf act ur e and sel l mechani cs'
t ool cases. They r ange i n pr i ce f r om$500. 00 f or a
somewhat i ncompl et e, l esser qual i t y set t o $1200. 00 f or
a mor e compl et e t op qual i t y set . These compani es ar e;
Campagnol o, Gi pi emme, Zeus, Bi cycl e Resear ch, and VAR.
They ar e al l l i st ed i n t he r esour ce l i st at t he end of
t he hook.
6- 1
WELDI NG TANKS AND APPARATUS
Ther e ar e sever al combi nat i ons of gasses t hat can
be used f or si l ver br azi ng. MAPP gas, Pr opane,
Hydr ogen, and Oxy- Acet yl ene ar e j ust a f ew.
Oxy- Acet yl ene i s by f ar t he most ver sat i l e and easi est
t o wor k wi t h. Ref i l l i ng i s al so easy. I t pr ovi des a
hot enough f l ame f or wel di ng when desi r ed. Pr eheat i s
qui ck. Hoses, t i ps, goggl es, gauges and st r i ker s can
be pur chased as a set . Ther e ar e sever al manuf act ur er s
t o choose f r om. I n choosi ng a br and of wel di ng
equi pment , make cer t ai n t o choose one t hat has ser vi ce
par t s r eadi l y avai l abl e, has f i t t i ngs t hat ar e
compat i bl e wi t h t he r est of t he i ndust r y and a pl ace
t hat i s cl ose by f or r ef i l l s. Tanks can be r ent ed on a
mont h- t o- mont h basi s or
"
pur chased
"
on a cont r act
basi s. ( The t anks ar e not act ual l y pur chased, but wi t h
a cont r act ar r angement , demur r age f ees can be avoi ded. )
Do not wast e t i me wi t h t anks smal l er t han 70 cubi c
f eet . Ref i l l i ng becomes a r eal bot her wi t h smal l er
t anks. About t wo or t hr ee f r ameset s can be bui l t wi t h
a set of 70 cu. f t . t anks bef or e r ef i l l i ng i s
necessar y.
VI SE
A good qual i t y vi se i s absol ut el y essent i al t o
f r amebui l di ng. Ther e ar e a mul t i t ude of vi ses on t he
mar ket wi t h many opt i ons t o choose f r om. I n choosi ng a
vi se l ook f or t he f ol l owi ng:
1 - At l east 4" j aws- - A smal l er vi se j ust doesn' t
have enough mass.
2 - Repl aceabl e j aws- - Fr amebui l di ng i s har d on vi se
j aws.
3 - A swi vel base- - Ther e ar e t i mes t hat t hi ngs must
be hel d i n an awkwar d posi t i on and swi vel i ng
hel ps a l ot .
6- 2
4 - Moveabl e f r ont j aw- - A vi se wi t h a moveabl e r ear
j aw wi l l not al l ow a pi ece of t ubi ng t o be hel d
ver t i cal l y wi t h t he excess st i cki ng down t owar d
t he f l oor .
5 - An Amer i can vi se- - The qual i t y of the al l oys
used i n Amer i can made vi ses i s f ar bet t er t han
t he ones comi ng out of t he Or i ent . Make sur e
t he vi se i s mount ed t o a ver y st ur dy base and
t hat t hat base i s secur el y mount ed t o ei t her
t he wal l or t he f l oor .
Utility Vises
31/2", 4", 5 Jaw Widths
Nos. 013 1/2, 014, 015
STARRETT CATALOGUE
FI LES
Iarretti MACHINISTS' VISES
Brass Vise Jaw Caps
Designed to cover serrated jaw faces snugly to
prevent marking of soft materials when held rigidly.
Speedily attached and removed
Fi l es ar e t he hear t of f r amebui l di ng. The f r ame
al most coul d not be bui l t wi t hout t hem, A good
sel ect i on of f i l es must be kept on hand. The f ol l owi ng
ar e r ecommendat i ons f or f i l es t o buy:
- 10" f l at , cour se, mi l l f i l e f or r oughi ng wor k
on out si de cor ner s and f l at sur f aces.
- 8" f l at , bast ar d or 2nd cut , mi l l f i l e f or wor k
on out si de cor ner s and f l at sur f aces.
- 6" f l at , smoot h, mi l l f i l e f or semi - f i ni shi ng
wor k.
- - 10" hal f r ound, cour se f i l e f or doi ng r oughi ng
wor k or f i l i ng l ar ger r adi i .
- 8" hal f r ound, bast ar d or 2nd cut f i l e f or
f i l i ng t he pr oper r adi i i n t he f r ont t r i angl e.
- 6" hal f r ound, smoot h f i l e f or f i l i ng br ake
br i dges.
- 8" and 10" r ound f i l e f or f i l i ng smal l er r adi i .
- Tr i angul ar f i l es ar e opt i onal .
6- 3
- -

One compl et e set of needl e f i l es f or doi ng t he

f i ni shi ng wor k.
Ri f f l er s ar e opt i onal . They ar e excel l ent f or
t i ght spot s but ver y expensi ve i t ems.
"Dead" f i l es must be r epl aced on a r egul ar basi s.
I n cut t i ng har d met al s l i ke Chr o- Mo st eel , f i l es wear
out f ast . The 8" f i l es wi l l be r eady t o be scr apped
af t er t en f r ames.
Keep handl es on al l f i l es at al l t i mes. The t ange
of a f i l e i s shar p and hazar dous.
Buy Amer i can f i l es. They ar e def i ni t el y made of
super i or mat er i al .
GRI NDI NG WHEELS
The best gr i ndi ng wheel set - up t o buy i s a mot or
wi t h an ar bor comi ng out of each end. Make sur e al l
saf et y devi ces wor k pr oper l y, i . e. el ect r i cal gr ound,
eye shi el ds and t ool r est s. To make t he gr i nder
par t i cul ar l y usef ul t o f r amebui l di ng, l ower one of t he
t ool r est s al l t he way and r ai se t he eye shi el d on t hat
same si de as f ar as possi bl e. Now dr ess t he wheel so
i t has a r ounded cont our . Thi s i s ver y usef ul f or
r oughi ng i n mi t er j oi nt s.
HAND OPERATED ELECTRI C DRI LL
A hand dr i l l i s necessar y f or dr i l l i ng ai r
expansi on hol es and al so f or oper at i ng any r ot ar y
devi ces such as hones, wi r e wheel s or sandi ng uni t s. I n
choosi ng a hand dr i l l l ook f or t he f ol l owi ng opt i ons:
1 - 3/ 8
"
chuck or bi gger t o al l ow use of l ar ger
bi t s. A l ar ger chuck i s al so easi er t o t i ght en
and l oosen.
2 - Var i abl e speed swi t ch - - Chr o- Mo st eel shoul d
be dr i l l ed at a ver y sl ow speed.
6- 4
PARK CATALOGUE
DRI LL BI TS
A compl et e set of dr i l l bi t s i n a dr i l l bi t i ndex
i s a good i dea. Dr i l l bi t s bangi ng ar ound i n a box or
dr awer t end t o get dul l f ai r l y f ast . Buy onl y Amer i can
made dr i l l bi t s f r oma r eput abl e sour ce. NO 99c
SPECI ALS! A 1/ 16" t o 1/ 4" set of bi t s wi t h sel ect ed
l ar ger bi t s i s sat i sf act or y.
PARR STAND
Par k Tool of Whi t e Bear Mi nnesot a makes t he best
bi cycl e st and i n t he wor l d. Not onl y does i t hol d
bi cycl es, but i t al so makes an excel l ent t ubi ng j i g t o
hol d t ubes whi l e f i l i ng mi t er s. The r ot at i on of t he
cl amp al so al l ows f or a mul t i t ude of posi t i ons i n
hol di ng wor k.
Al so made by Par k i s t he f r ame al i gnment st and.
Thi s cl amps and l ocat es of f t he bot t ombr acket and
al l ows f ai r l y pr eci se al i gnment checki ng. The st and
can al so be used f or cer t ai n col d set t i ng oper at i ons.
The f r ame al i gnment st and can al so be or der ed wi t h a
bi cycl e st and mount ed t o t he t op of i t .
6-5
PRECI SI ON TOOLS
Fi ve pr eci si on t ool s ar e wor t h ment i oni ng her e.
They ar e:
THE MACHI NI ST' S SQUARE
The machi ni st ' s squar e can be used t o check
squar eness of mi t er s and f or t r ansf er r i ng l i nes and
measur ement s up f r oma sur f ace pl at e.
THE VERNI ER CALI PER
The ver ni er cal i per i s good f or f i ne measur ement s
i n many i nst ances. Buy one wi t h bot h Met r i c and
Engl i sh scal es.
THE BEVEL PROTRACTOR
The bevel pr ot r act or can be used t o check mi t er
angl es.
ARR CA AL C
THE COMBI NATI ON SQUARE WI TH LEVELI NG BUBBLE
The combi nat i on squar e wi t h l evel i ng bubbl e can be
used t o check f r ame angl es on a bui l t up bi ke as wel l
as l evel i ng t he r ear end j i g and doubl e checki ng angl es
on an i ncompl et e f r ame.
VBLOCKS
Vbl ocks can be used t o suspend wor k above t he
dr awi ng as i t si t s on a sur f ace pl at e.
6- 7
V Block and Clamp
Hardened
and Ground
;1
6 Inch
No. 567
No. 567 V Block and Clamp shown above
STARRETT CATALOGUE
DI E GRI NDER
Di e gr i nder s ar e ver y usef ul f or hi gh speed cut t i ng
of ext r emel y har d mat er i al . Gr i ndi ng i nsi de t i ght
pl aces l i ke i nsi de t he bot t ombr acket shel l i s possi bl e
wi t h a di e gr i nder . An abr asi ve di sc can be mount ed i n
t he ar bor t o cr eat e an abr asi ve cut - of f wheel . Thi s i s
par t i cul ar l y usef ul i n cut t i ng t he seat post bi nder
sl ot . I n buyi ng st ones and wheel s f or t he di e gr i nder ,
be sur e t o get ones wi t h r at i ngs f or 25, 000 r pmor
f ast er .
DRAWI NG BOARD
A sat i sf act or y dr awi ng boar d can be made f or under
$20. 00. Al l t hat i s needed i s f l at dr awi ng sur f ace and
a means of dr awi ng consi st ent hor i zont al l i nes. The
boar d can be made out of 3/ 4" AC pl ywood measur i ng 3' x
4
'
. A T- squar e can be used t o dr aw t he hor i zont al
l i nes. Al l ot her l i nes can be l ocat ed wi t h a l ar ger
6- 8
pr ot r act or and dr awn wi t h a st eel st r ai ght edge. The
ot her end of t he spect r umi s t o spend hundr eds of
dol l ar s on a ver y exqui si t e dr af t i ng t abl e and
accessor i es.
DRI LL PRESS
A dr i l l pr ess i s def i ni t el y a l uxur y t hat most
begi nni ng f r amebui l der s can get al ong wi t hout .
However , i f buyi ng one, ei t her a bench or f l oor model
i s f i ne. A 6
"
t o 10" dr i l l pr ess i s l ar ge enough f or
f r amebui l di ng wor k. A t i l t i ng head or t abl e i s usef ul
but not necessar y.
AI R COMPRESSOR
An ai r compr essor i s not a necessi t y f or
f r amebui l di ng but t he advant ages i t of f er s of t ent i mes
cannot easi l y be passed up. The most i mmedi at e use of
t he ai r compr essor i s f or f ast and t hor ough cl eani ng
and dr yi ng of par t s i n pr epar at i on f or si l ver br azi ng.
The ai r compr essor al l ows t hemt o be bl own dr y bef or e
r ust set s i n. I t al so dr i es wi t hout cont ami nat i ng t he
sur f ace wi t h oi l or mor e di r t . For t hi s t ype of use
l ook f or a compr essor wi t h a 110 vol t mot or , a smal l er
t ank, and a si ngl e cyl i nder . The compr essor can be
used t o r un sever al ai r power ed t ool s such as; di e
gr i nder s, dr i l l s, Dynabr ade sander s, et c. I f usi ng a
compr essor t o t hi s ext ent , l ook f or one wi t h a 220 vol t
mot or , t wo cyl i nder s, and at l east a 25 gal l on t ank.
Last of al l , a compr essor can be used f or pai nt i ng. I n
choosi ng a compr essor f or pai nt i ng pur poses, make sur e
i t has separ at e gauges f or t ank and l i ne pr essur es,
6- 9
SEARS CATALOGUE
moi st ur e f i l t er , and can del i ver enough cubi c f eet per
mi nut e t o sat i sf y pai nt gun specs. ( Not e: I f usi ng
t he compr essor t o r un ai r t ool s and pai nt , r un separ at e
l i nes f or bot h oper at i ons so oi l doesn' t back- up i nt o
t he pai nt l i ne. )
SEARS CATALOGUE
BELTSANDER
A bel t sander i s def i ni t el y a l uxur y. I t can speed
up sever al cl ean- up oper at i ons as wel l as chew up met al
and spi t i t out f ast er t han anyt hi ng. Thi s i s a hi nt .
Onl y t he most exper i enced f r amebui l der s shoul d be usi ng
a bel t sander . A pi ece of met al can be r ui ned i n a
mat t er of seconds on t he bel t sander . I f pur chasi ng
one, buy a bench mount model whi ch can be adj ust ed t o
ver t i cal as wel l as hor i zont al wor k.
Anot her opt i on i n bel t sander s i s t he nar r ow bel t ,
hobby t ype sander . Thi s woul d be bet t er f or t he
begi nner t o exper i ment wi t h. I t doesn' t r emove met al
near l y as f ast .
6- 10
DYNABRADE BELT SANDER
The Dynabr ade bel t sander uses a t i ny 1/ 4" wi de
bel t t hat can get i nt o t he t i ght est of pl aces. I t i s
good f or doi ng cont our wor k on i nsi de and out si de
cor ner s. I t i s an expensi ve uni t ( $300. 00) t hat shoul d
onl y be used by a ski l l ed cr af t sman. I t t oo i s a
"
met al eat er " t hat can do a l ot of damage i n t he wr ong
hands. However , used by a ski l l ed hand i t has
capabi l i t i es of doi ng excel l ent f i ni sh wor k. I t comes
i n ai r - power ed or el ect r i cal - power ed.
THE FI T KI T
Pr oduced and mar ket ed by t he New Engl and Cycl i ng
Academy ( NECA) , t hi s ki t answer s al l si zi ng quest i ons
per t ai ni ng t o a good mat ch bet ween bi ke and r i der . I n
addi t i on, t he Rot at i onal Adj ust ment Devi ces ( RAD)
pr ovi ded al l ow t he most exact i ng adj ust ment of cl eat ed
shoes. ( See NECA i n t he r esour ce sect i on. )
6- 11
THE FRAME ALIGNMENT SYSTEM
Thi s por t abl e, hi gh pr eci si on syst emwi l l det ect
and measur e al l cr i t i cal f r ame al i gnment usi ng t he
cent r al movement as a r ef er ence. I t wor ks wel l on new
f r ames and f or ks as wel l as damaged ones.
t he r ef er ence - t i on.
( See NECA i n
TWO FINAL ITEMS
No shop shoul d be wi t hout a f i r e ext i ngui sher and a
f i r st ai d ki t . Make sur e t he f i r e ext i ngui sher i s
upt odat e and has an ABC r at i ng. Al ways keep t he
f i r st ai d ki t r epl eni shed wi t h par t i cul ar at t ent i on
pai d t o suppl i es f or bur ns and mi nor cut s. Fi r e,
Pol i ce and Ambul ance phone number s shoul d be post ed
next t o t he phone.
6- 12
FRAMEBUI LDER' S RESOURCE LI ST
The f ol l owi ng r esour ce l i st has been made wi t h t he
f r amebui l der speci f i cal l y i n mi nd. Onl y suppl i er s of
t he r aw mat er i al s necessar y f or bi cycl e f r amebui l di ng
have been i ncl uded i n t hi s l i st . The suppl i er s ar e
l i st ed i n 4 cat egor i es as f ol l ows:
M

These ar e manuf act ur er s of pr oduct s and sel dom,

i f ever , deal wi t h cust omer s at t he r et ai l er or
r et ai l l evel . I n deal i ng wi t h t hese
manuf act ur er s, i t i s best j ust t o r equest a
br ochur e and t he name of t he near est out l et
whi ch can handl e t he needs of t he i ndependent
f r ame bui l der .
These ar e compani es who br i ng pr oduct s i n f r om
ot her count r i es i n l ar ge quant i t i es. They deal
pr i mar i l y wi t h whol esal er s. I n deal i ng wi t h
t hese out f i t s, i t i s best j ust t o r equest t he
name of t he near est out l et whi ch can handl e t he
needs of t he i ndependent f r amebui l der .
W These ar e whol esal er s or
"
j obber s
"
. They
usual l y deal di r ect l y wi t h manuf act ur er s and
i mpor t er s and somet i mes i mpor t i t ems
t hemsel ves. Many whol esal er s ar e mor e t han
happy t o handl e t he speci f i c needs of
i ndependent f r amebui l der s. However , t hey wi l l
have some expect at i ons of t he bui l der .
1 - - Be r eady wi t h a busi ness phone l i st i ng.
2 - - Have a st at e Ret ai l er ' s Per mi t f r omt he
st at e Revenue Depar t ment .
3 - - Be r eady t o buy t hi ngs i n quant i t y.
4 - - Be pr epar ed t o pay on a C. O. D. basi s f or
as l ong as t he f i r st year of doi ng
busi ness wi t h t hem.
5 - - A Pr of i t and Loss st at ement or a f i nanci al
st at ement may be r equest ed.
Ot her i t ems t hat may hel p i n deal i ng wi t h
whol esal er s ar e:
1 - - Have a busi ness car d.
2 - - Have pr of essi onal st at i oner y.
3 - - Mai nt ai n a busi ness checki ng account .
R

These ar e r et ai l er s. They sel l t o anyone who

wal ks i n of f t he st r eet . They sel dom, i f ever ,
r equi r e mi ni mumpur chases. A good r et ai l er
wi l l go t o gr eat l engt hs t o get a pr oduct f or a
pr ef er r ed cust omer . The r et ai l er char ges f ul l
r et ai l pr i ce f or goods sol d and shoul d be pai d
t hat pr i ce. ( I f t he bui l der bal ks at payi ng
7- 1
r et ai l pr i ces, t hen he shoul d go t hr ough t he
hassl es necessar y t o deal wi t h t he whol esal er . )
I n t he f ol l owi ng l i st t he pr oper l et t er
cl assi f i cat i on will f ol l ow t he busi ness name i n
par ent heses. I f t he f i r m desi r es busi ness f r om
f r amebui l der s i n par t i cul ar , a l et t er "F" will appear
al so. Si nce some of t he f ol l owi ng busi nesses may
f al l under mor e t han one cl assi f i cat i on, t her e may be
mor e t han one l et t er l i st ed.
FRAMEBUILDER'S RESOURCE LIST
BENOTTO BI CYCLES U. S. A. ( I , W, F)
544 W. LASTUNAS DRI VE
SAN GABRI EL, CA 91776
1- 818- 576- 2222
I mpor t er s of t he Benot t o f r ame si zi ng st and ( #008038) .
Thi s mock- up of a bi cycl e i s f ul l y adj ust abl e t o f i t
any pr ospect i ve cust omer . I t ' s a good uni t t o use
whi l e maki ng t he wor ki ng dr awi ng.
( M, W) BI CYCLE RESEARCH
1300 GALI NDO STREET
CONCORD, CA 94520
1- 415- 825- 4223
Manuf act ur er s of bi cycl e t ool s i ncl udi ng t aps, t ap
hol der s, and hand mi l l i ng t ool s f or head and bot t om
br acket . Al so of f er shar peni ng ser vi ce f or ot her br and
cut t er s. ( See Phi l Wood)
BI LL DAVI DSON CYCLES ( I , W, F)
2116 WESTERN AVE.
SEATTLE, WA 98121
1- 206- 682- 8226
I mpor t er s of a l i ne of hi gh qual i t y i nvest ment cast
l ugs, bot t ombr acket shel l s and f or k cr owns. Mi ni mum
or der - 10 set s.
BI NKS
( M)
9201 WEST BELMONT AVE.
FRANKLI N PARK, I L 60131
1- 312- 671- 3000
Manuf act ur er s of spr ay pai nt i ng equi pment - t he Bi nks
model #115 gun i n par t i cul ar . Al so manuf act ur er s of
saf et y br eat hi ng uni t s.
7- 2
BLACKBURN DESI GN, J I M ( M, F)
75 CRI STI CH LANE
CAMPBELL, CA 95008
1- 408- 371- 0992
Bl ackbur n i s t he desi gner / manuf act ur er of t he
hi ghl y- r egar ded l i ne of car r i er s. They have a
l ong- st andi ng pol i cy of co- oper at i ng cl osel y wi t h
pr of essi onal cust omf r amebui l der s. The ext ent of t he
ser vi ces t hat t hey pr ovi de r ange f r omt echni cal
speci f i cat i ons t o br aze- on bi t s t o or i gi nal equi pment
( O. E. M. ) sal e of t hei r pr oduct s. Al l t hi s wi t h t he
goal of mat chi ng t he best r ack t o t he best bi ke.
Pr of essi onal f r amebui l der s ar e encour aged t o cal l or
wr i t e.
BROWN & SHARP ( M)
PRECI SI ON PARK
NORTH KI NGSTON, RI 02852
1- 401- 886- 2000
Manuf act ur er s of hi gh pr eci si on t ool s. Most not abl y
f or f r amebui l di ng ar e V- bl ocks, di al i ndi cat or s,
ver ni er cal i per s, hei ght gages, mi cr omet er s, pr eci si on
gr ound f l at st ock, and bevel pr ot r act or s.
CAMPAGNOLO USA, I NC. ( I )
P. O. BOX 37426
HOUSTON, TX 77036
Amer i can di st r i but or s of I t al i an made bi cycl e
component s. Most not abl y f or f r amebui l di ng ar e t hei r
l i ne of br aze- ons and dr opout s.
COMPONENT COMPANY ( W)
801 W. MADI SON STREET/ P. O. BOX 95
WATERLOO, WI 53594
1- 800- 558- 0146
Di st r i but or s of bi cycl e par t s and component s. For
f r amebui l der s t hey have a l i mi t ed sel ect i on of l ugs,
bot t ombr acket s, t ube set s and br aze- ons.
CONSORI ZI O PRI MO ( I )
10250 BI SSI ONNET - SUI TE 330
HOUSTON, TX 72036
1- 713- 981- 1934
I mpor t er s of t he compl et e l i ne of Col umbus and Ci nel l i
bi cycl e f r amebui l di ng component s as wel l as Ci nel l i
f r amebui l di ng f i xt ur es.
7- 3
CYCLE GOODS ( R, F)
2735 HENNEPI N AVE. S.
MI NNEAPOLI S, MN 55408
1- 800- 328- 5213
Cycl e Goods sel l s Col umbus, Ci nel l i , Reynol ds, Tange,
and Campagnol o f r amebui l di ng suppl i es i ncl udi ng t ube
set s, l ugs, bot t ombr acket shel l s, cr owns, dr opout s,
and br aze- ons. They shi p UPS C. O. D. or accept maj or
cr edi t car ds.
DI TZLER AUTOMOTI VE FI NI SHES PPG I NDUSTRI ES I NC. ( M)
P. O. BOX 3510
TROY, MI 48084
Manuf act ur er s of pol yur et hane enamel s, acr yl i c enamel s,
acr yl i c l acquer s and ot her pai nt i ng pr oduct s.
DUPONT DE NEMOURS & CO. , I NC. ( M)
WI LMI NGTON, DL 19898
1- 800- 323- 6004 OR 1- 800- 400- 9475
Manuf act ur er s of pol yur et hane enamel s, acr yl i c enamel s,
acr yl i c l acquer s, epoxy pr i mer s and ot her pai nt i ng
pr oduct s.
DYNABRADE I NC. ( M)
72 E. NI AGARA STREET
TONAWANDA, NY 14150
1- 716- 694- 4600 OR 1- 800- 828- 7333
Uni que por t abl e abr asi ve bel t machi nes f or gr i ndi ng,
bl endi ng, and pol i shi ng i n nor mal l y i naccessi bl e ar eas.
The Dynaf i l e of f er s except i onal ver sat i l i t y, accept i ng
over t went y di f f er ent cont act ar ms t o mat ch t he needs
of a par t i cul ar appl i cat i on.
EUTECTI C
40- 40 172nd STREET
FLUSHI NG, NY 11358
1- 800- 323- 4845
Manuf act ur er s of br azi ng, wel di ng, and sol der i ng al l oys
as wel l as ot her compounds f or speci al met al l ur gi cal
uses.
FI SHER MOUNTAI N BI KES ( M, W, F)
1501 SAN ANSELMO AVENUE
SAN ANSELMO, CA 94960
1- 415- 459- 2247
Bui l der s of t he Fi sher l i ne of mount ai n bi kes. Al so
whol esal er s of mount ai n bi ke f r amebui l di ng suppl i es.
7- 4
FRAME BUI LDER' S GUI LD ( F)
RT. 2, BOX 234
RI VER FALLS, WI 54022
Pr esent l y wor ki ng on f r amebui l di ng cer t i f i cat i on, gr oup
i nsur ance f or f r amebui l der s and desi gn and manuf act ur e
of f i xt ur es.
FUTURE METALS ( W)
905 W. NORTH CARRI ER PARKWAY
GRAND PRAI RI E, TX 75050
1- 800- 527- 1631
Di st r i but or s and sel l er s of chr ome- mol y ai r cr af t
t ubi ng.
HANDY & HARMON ( M, W, F)
850 3r d AVE.
NEWYORK, NY 10022
1- 212- 752- 3400
Manuf act ur er s of wel di ng, br azi ng and sol der i ng al l oys-
Easy Fl o 30 and Handy Fl ux i n par t i cul ar .
HENRY J AMES BI CYCLES, I NC. ( M, F)
704- P ELVI RA AVE.
REDONDO BEACH, CA 90277
1- 213- 540- 1552
Henr y J ames of f er s Amer i can- made i nvest ment cast f r ame
component s. Lugs and bot t ombr acket shel l s ar e of f er ed
i n a f ul l r ange of angl es. Road, Tandemand mount ai n
cr owns ar e si zed f or Col umbus and New Reynol ds oval s.
Li ght wei ght dr opout s ar e a new addi t i on i n bot h al l oy
and st ai nl ess st eel . Most component s ar e avai l abl e i n
st ai nl ess st eel . Send sel f - addr essed st amped envel ope
f or l i t er at ur e and pr i ces.
HI GH BRI DGE - TAKAHASKI PRESS CO. LTD. ( M)
30- 9HI GASHI NI PPORI 1- CHOME
ARAKAWAKU
TOKYO, 116 J APAN
TEL: 03 ( 807) 3187
Manuf act ur er s of a compl et e l i ne of f or k cr owns,
dr opout s and br aze- ons.
I SLAND CYCLE SUPPLY CO. ( W, F)
425 WASHI NGTON AVE.
MI NNEAPOLI S, MN 55401
1- 612- 333- 7771
Whol esal er s and r et ai l er s of t he compl et e l i ne of
Ci nel l i , Col umbus, Reynol ds, and Campagnol o
f r amebui l di ng suppl i es as wel l as many ot her t op
qual i t y bi cycl e pr oduct s.
7- 5
J.W. HARRI S CO. I NC. ( M)
CI NCI NNATI , OH 45242
Manuf act ur er s of St ay Si l v si l ver br azi ng al l oys and
Saf e Si l v cadmi umf r ee si l ver br azi ng al l oy.
LEE KATZ ( W, I , F)
1015 DAVI S STREET
EVANSTON, I L 60201
1- 800- 227- 2453
Whol esal er s of a compl et e l i ne of Campagnol o, Reynol ds,
Vi t us, Dur af or t , Mi cr o Fusi one, Col umbus and Ci nel l i
f r amebui l di ng suppl i es i ncl udi ng t ube set s, l ugs,
bot t ombr acket shel l s, cr owns, and br aze- ons. They
al so sel l t he SAPO f r ame al i gnment syst em.
MI TUTOYO - MTI CORP. ( M)
18 ESSEX RD.
PARAMUS, NJ 07652
1- 201- 368- 0525
Manuf act ur er s of hi gh pr eci si on t ool s. Most not abl y
f or f r amebui l di ng ar e V- bl ocks, di al i ndi cat or s,
ver ni er cal i per s, hei ght gages, mi cr omet er s, pr eci si on
gr ound f l at st ock, and bevel pr ot r act or s.
NEWENGLAND CYCLI NG ACADEMY ( M, F)
MERI DEN ROAD
LEBANON, NH 03230
1- 603- 448- 5423
The New Engl and Cycl i ng Academy was or i gi nal l y f ounded
as a summer t r ai ni ng camp of f er i ng ser i ous and
r esponsi bl e i nst r uct i on t o aspi r i ng r aci ng cycl i st s of
al l ages. Wor ki ng wi t h i t s st udent s, t he Academy
devel oped THE FI T KI T . Thi s syst emdet er mi nes opt i mum
f r ame di mensi ons as wel l as pr oper l y si zed component
sel ect i on. The ROTATI ONAL ADJ USTMENT DEVI CES i ncl uded
i n THE FI T KI T ar e used t o pr eci sel y al i gn t he cl eat s
on cycl i ng shoes so t hat no medi al or l at er al st r esses
ar e i nduced on t he knee.
The Academy al so pr oduces THE FRAME ALI GNMENT SYSTEM.
Thi s i s a por t abl e syst emt o check and col d set a f r ame
i nt o al i gnment .
Ot her ser vi ces of f er ed by t he Academy ar e Pr of essi onal
vi deo pr oduct i ons, cl i ni cs and consul t i ng.
7- 6
OSELL, TERRY ( W, F)
1003 27t h AVE. S. E.
MI NNEAPOLI S, MN 55414
1- 612- 331- 2723
Cust omf r amebui l der - wi l l shi p smal l or der s of t ube
set s, br aze- ons, l ugs and bot t ombr acket shel l s on a
pr epai d basi s.
PARK TOOL ( M)
2250 WHI TE BEAR AVE.
ST. PAUL, MN 55109
1- 612- 777- 9768
Manuf act ur er of a compl et e l i ne of bi cycl e t ool s.
For f r amebui l der s t hey amke an excel l ent f l oor mount ed
f r ame al i gnment j i g.
PI NTO I MPORTS, MEL ( I , W)
P. O. BOX 2198
FALLS CHURCH, VA 22042
1- 703- 237- 4686
We sel l pr of essi onal qual i t y t ool s, and t he suppor t i ng
component r y t o bui l d bi cycl es, i ncl udi ng t andems. A
f ew exampl es f ol l ow: Vi ner , Al an, Romani , T. A. ,
St r ongl i ght , Campy, CLB, Regi na, Ci nel l i , I deal e,
Br ooks, Avocet , Cor t i na, Hur et , Si mpl ex, Bl uemel s,
LaPr eal pi na, Si l ca, Hi t e, Zef al , Par k, Var , BRC, Mavi c,
Ambr osi o, Fi amme, Super Champi on, Wei nmann, Vi t t or i a,
Wol ber , Mel Pi nt o Speci al Tandems and t andem
component s.
QUALI TY BI CYCLE PRODUCTS ( W, F)
2550 WABASH
ST. PAUL, MN 55114
1- 800- 346- 0004
Bi cycl e par t s whol esal er . Good sel ect i on of br aze- ons,
t ube set s, l ugs, bot t ombr acket s, and f or k cr owns.
R & E CYCLES ( R, M, W, F)
5627 UNI VERSI TY WAY N. E.
SEATTLE, WA 98105
Manuf act ur er s of Rodr i guez t andems and whol esal er s of
t andemf r amebui l di ng suppl i es.
SANTANA CYCLES I NC. ( W, M, F)
BOX 1205
CLAREMONT, CA 91711
1- 714- 621- 6943
Maj or i mpor t er of I shi wat a t ubi ng. Wi l l al so sel l
br aze- ons and Sant ana/ I shi wat a t andemt ube set s t o
i ndependent f r amebui l der s. Al so sel l s Col umbus t andem
t ube set s.
7- 7
SEROTTA CYCLES ( M, F, R)
GRANGE ROAD
GREENFI ELD CENTER, NY 12833
1- 518- 587- 9085
Manuf act ur er s and sel l er s of t he Ser ot t a si ze cycl e -
an adj ust abl e
"
mock- up" bi cycl e f r ame whi ch i s usef ul
f or si zi ng a r i der on a f r ame t hat i s yet t o be bui l t .
SHERWI N WI LLI AMS CO. ( M)
P. O. BOX 60277
CLEVELAND, OH 44115
1- 800- 223- 0431
Manuf act ur er s of pol yur et hane enamel s, acr yl i c enamel s,
acr yl i c l acquer s and ot her pai nt pr oduct s.
SHI MANO SALES CORP. ( I , M, F)
P. O. BOX 2775, 9530 COZY CROFT AVE.
CHATSWORTH, CA 91311
1- 213- 767- 7777
I mpor t er s of t he Tange br and f r ame t ube set s. Al so
Amer i can br anch of t he J apanese Shi mano Company -
manuf act ur er s of dr opout s, bot t ombr acket shel l s, f or k
cr owns, l ugs and br aze- ons. Cat al ogues avai l abl e on
r equest .
SNAP- ON TOOLS CORP.
( M)
KENOSHA, WI 53141- 2801
1- 800- 242- 4391
Manuf act ur er s of basi c shop t ool s usef ul t o t he bi cycl e
t r ade.
( M, W, F) SPEED RESEARCH
P. O. BOX 6776
BEND, OR 97708
1- 503- 389- 4313
Manuf act ur er s of t he ci r cumf er ence si zi ng t ool f or
checki ng i nsi de di amet er s of seat t ubes.
STARRETT
( M)
ATHOL, MA 01331
1- 617- 249- 3551
Manuf act ur er s of hi gh pr eci si on t ool s. Most not abl y
f or f r amebui l di ng ar e V- bl ocks, di al i ndi cat or s,
ver ni er cal i per s, hei ght gages, mi cr omet er s, pr eci si on
gr ound f l at st ock, and bevel pr ot r act or s.
7- 8
STRAWBERRY RACI NG CYCLES ( I , W, F)
530 N. W. 9t h AVE.
PORTLAND, OR 97209
1-800-321-5532
We bui l d a smal l number of f r ames. Pl ease f i nd bel ow an
al phabet i cal l i st i ng of suppl i er s whose pr oduct s we
di st r i but e, of t he I t al i an company Mar chet t i & Lange
f or whomwe ar e t he USA agent , and t he f ew t ool s, par t s
and ser vi ce St r awber r y Cycl espor t I nc. sel l s.
BOCAMA: Lugs, f or k cr owns, bot t ombr acket s
COLUMBUS: Tubi ng
GI PI EMME: Br aze- on' s, f or k/ st ay ends, t ool s
EPS: Fr ont der ai l l eur br aze- on f i xt ur e, f or k br azi ng
f i xt ur e.
MARCHETTI & LANGE: Bi cycl e f abr i cat i on t ool i ng
STRAWBERRY CYCLESPORT I NC. : Car bi de i nser t and H. S. S.
t ube mi t r e cut t er s, br azi ng r od, br azi ng f l ux,
cut t er shar peni ng ser vi ce.
VAR: Fr ame mi l l i ng and bi cycl e assembl y t ool s.
SUNTOUR USA ( I , M)
10 MADI SON ROAD
FAI RFI ELD, NJ 07006
1- 201- 575- 1128
The Amer i can br anch of t he J apanese Sunt our Company.
They of f er a compl et e sel ect i on of dr opout s and a f ew
br azed- on shi f t l ever set s and br azed- on f r ont
der ai l l eur s.
SUTHERLAND' S BI CYCLE SHOP AI DS ( M, W)
BOX 9061
BERKELEY, CA 94709
Publ i sher of t he Sut her l and
'
s Manual . Thi s manual
gi ves compl et e specs t hat any f r amebui l der woul d need
t o know wi t h concer n t o bear i ngs, t hr eads, and ot her
cr i t i cal si zes. Al so i n t he manual ar e det ai l ed
descr i pt i ons of how t o use cut t i ng t ool s.
T. I . STURMEY- ARCHER OF AMERI CA ( I , W, M, F)
1014 CAROLI NA DRI VE
WEST CHI CAGO, I L 60185
1- 800- 323- 9194
The Amer i can br anch of St ur mey- Ar cher of Engl and and
r el at ed t o T. I . Reynol ds and T. I . Ral ei gh. They ar e
t he Amer i can I mpor t er s f or Reynol ds f r ame t ubi ng and
Haden l ugs, cr owns, bot t ombr acket s, and br aze- ons.
Car r yi ng t ubi ng set s and l ugs f or pr of essi onal
f r amebui l der s. Some f i l ms and vi deo f or gener al
consumpt i on and use wi t h bi cycl e cl ubs.
7- 9
Al so f ul l l i ne of STURMEY- ARCHER and Br ooks saddl es,
f eat ur i ng t he new ELI TE al l oy br ake hubs and Col t
Aer o- desi gn saddl es.
Al so compl et e l i ne of pr of essi onal wheel bui l di ng
machi ner y and r obot i cs.
TEN SPEED DRI VE ( I , W)
131 TOMAHAWK DRI VE UNI T 6
I NDI ANA RI VER BEACH, FL 32937
1- 305- 777- 5777
Ten Speed Dr i ve I mpor t s, I nc. an aut hor i zed di st r i but or
and i mpor t er f or Col umbus t ubi ng, Ci nel l i l ugs and
f r ame bui l di ng equi pment and Ten Speed Dr i ve br aze- on
component s, di st r i but es t o r et ai l bi cycl e st or es and
f r amebui l der s t hr oughout t he U. S. For mor e i nf or mat i on
cont act t he above addr ess.
( I , W, F) TORELLI I MPORTS
P. O. BOX 3163
2388 E. LAS POSAS ROAD
CAMARI LLO, CA 93010
1- 805- 484- 8705
I mpor t er s and whol esal er s of t he Cobr a l i ne of t ool s.
TRUE TEMPER CYCLE ( M)
871 RI DGEWAY LOOP, SUI TE 201
MEMPHI S, TN 38119
1- 901- 767- 9411
Manuf act ur er s of Amer i can- made but t ed bi cycl e t ubi ng
set s.
UNI ON CARBI DE CORP. - LI NDE DI VI SI ON ( M)
270 PARK AVE.
NEWYORK, NY 10017
1- 800- 325- 8501
Manuf act ur er s of wel di ng pr oduct s and pr oducer s of
bot t l ed gasses.
UNI TED BI CYCLE TOOL SUPPLY ( W) or : THE THI RD HAND ( R)
12225 HWY 66
ASHLAND, OR 97520
1- 503- 482- 1750
I mpor t er s and sel l er s of t he most compl et e sel ect i on of
bi cycl e t ool s i n t he U. S. RETAI L SHOPS addr ess al l
i nqui r i es t o Uni t ed Bi cycl e Tool Suppl y. Peopl e
wi t hout a busi ness phone l i st i ng or st at e t ax per mi t
addr ess al l i nqui r i es t o The Thi r d Hand.
7- 10
VAR
( M, W)
6, RUE PASTEUR
75011 - PARI S
FRANCE
TEL: 700. 03. 88
355. 26. 64 or 700. 01. 16
Manuf act ur er s of ver y speci al i zed bi cycl e t ool s.
WI LSON, G. P. ( M, F)
1668 CHALCEDONY STREET
SAN DI EGO, CA 92109
1- 619- 272- 2434
Manuf act ur er s of hi gh qual i t y i nvest ment cast st ai nl ess
st eel dr opout s. Wi l l f i l l smal l or der s on a pr epai d
basi s onl y.
WOOD, PHI L
( M, W)
153 W. J ULI AN STREET
SAN J OSE, CA 95110
1- 408- 298- 1540
Manuf act ur er of hi gh qual i t y bi cycl e component s.
Goods: 1) 11/ 4 Round chr ome- mol y t ubi ng - . 035 or
. 049wal l .
2) . 800 x 1. 600 Oval t ubi ng - same wal l
t hi cknesses.
3) Cr ankshaf t s f or speci al f r ames ( st r ai ght
di amet er f or pr essed on bear i ngs)
4) Bi cycl e Resear ch Pr oduct s Fr ame machi ni ng
t ool s.
7- 11
LUGLESS BUI LDI NG
Most of t hi s manual i s devot ed t o si l ver br azed l ugged
f r amebui l di ng. However . t hi s i s not t he onl y opt i on i n
f r amebui l di ng. Many bui l der s choose t o bui l d wi t hout t he use of
l ugs. Ther e ar e t hr ee mai n r easons f or choosi ng t o bui l d
l ugl ess:
1. Use of over si zed t ubes somet i mes makes i t i mpossi bl e t o
use l ugs. Most l ug set s ar e made f or bi kes wi t h
st andar d Br i t i sh or Fr ench t ube di amet er s. Thus, when
bui l di ng t andems wi t h l ar ge chai nst ays, 1- 3/ 8" down
t ube, 1- 1/ 8" t op t ubes, and an oval bot t omt ube or when
bui l di ng mount ai n bi kes wi t h 1- 1/ 4" down t ubes and
1- 1/ 8" t op t ubes, ver y f ew i f any sui t abl e l ugset s ar e
avai l abl e.
2. Non- st andar d desi gns of t en el i mi nat e t he possi bi l i t y of
usi ng l ugs. Bui l di ng a f r ame wi t h a r adi cal l y sl opi ng
t op t ube, a f r ame t hat al l ows t he r ear wheel t o come
bet ween t wi n seat t ubes, a f r ame t hat i s hi ghl y
exper i ment al i n desi gn, or bui l di ng a r ecumbent ar e al l
si t uat i ons whi ch coul d r equi r e l ugl ess const r uct i on.
3. Lugl ess bui l di ng i s def i ni t el y a f ast er pr ocess. Labor
can be cut by anywher e f r om15 t o 30 per cent , dependi ng
on whi ch t ype of l ugl ess const r uct i on i s used.
As mi ght be expect ed, t her e ar e al so di sadvant ages t o l ugl ess
bui l di ng. One mai n di sadvant age i s t emper at ur e. Al l f or ms of
l ugl ess bui l di ng ar e hot t er t han si l ver br azed const r uct i on.
Some f or ms of l ugl ess bui l di ng ar e onl y a coupl e hundr ed degr ees
hot t er , but ot her f or ms ar e over a t housand degr ees hot t er . Heat
causes di st or t i on and anneal i ng f r omsl ow cool i ng. I t causes
embr i t t l ement f r omf ast cool i ng. A bui l der want s t o deal wi t h
t hese t hr ee pr obl ems as l i t t l e as possi bl e.
Thi s sect i on of THE PATEREK MANUAL cover s l ugl ess bui l di ng as
a suppl ement t o t he bui l di ng a f r amebui l der i s al r eady doi ng.
Pl ease keep i n mi nd t hat t he aut hor i s not sayi ng t o bui l d onl y
l ugl ess f r ames. Nor i s he sayi ng don' t bui l d l ugl ess. Ther e ar e
appl i cat i ons f or bot h t ypes of const r uct i on and a t r ul y t al ent ed
bui l der can swi ng back and f or t h bet ween bot h. The f ol l owi ng
pages cover t he mai n t ypes of l ugl ess bui l di ng used i n t he
bi cycl e i ndust r y. The sect i on t hen f i ni shes up wi t h a checkl i st
f or l ugl ess bui l di ng whi ch can be used i n conj unct i on wi t h t he
checkl i st appear i ng ear l i er i n t he book.
8- 1
EXTERNAL FI LLET BRAZI NG ( LARGE FI LLETS)
Thi s i s t he t ype of j oi nt seen on many l ugl ess t andems and
hi gh qual i t y mount ai n bi kes. The t ubes ar e mi t er ed t he same way
as l ugged j oi nt s. The mi t er ed j oi nt i s t hen t acked and checked
t o see i f t he angl e i s cor r ect . The bui l der t hen sl owl y bui l ds
up t he j oi nt t i l l a l ar ge f i l l et i s f or med al l t he way ar oud t he
j oi nt . Excess br azi ng mat er i al i s f i l ed and gr ound away,
t aki ng gr eat car e not t o r emove any st eel adj acent t o t he j oi nt y.
Sandi ng i s done wi t h st r i ps of emer y cl ot h f or a f i ne f i ni sh.
M! R O} ! F! ! H O} !
.JJ5 xI f I ( f I )
EXTERNAL FI LLET BRAZI NG ( SMALL FI LLET)
Thi s i s a t ype of j oi nt f ound on l ess expensi ve f r ameset s.
Maki ng a smal l er f i l l et i s a way t o cut cost s whi l e at t he same
t i me sacr i f i ci ng some i n t he way of qual i t y. Si nce t he f i l l et s
ar e smal l er , t hey can not be smoot hed out as easi l y and ar e j ust
as wel l l ef t unt ouched af t er br azi ng. Smal l er f i l l et s have one
di st i nct advant age over l ar ger ones; t her e i s l ess heat
di st or t i on wi t h t he smal l er f i l l et .
.JJ6 xI f I ( m f I)
B-2
brazing
alloy
I NTERNAL FI LLET BRAZI NG
Ver y f ew bi kes ar e bui l t wi t h i nt er nal f i l l et br azi ng. I t i s
a pr ocess t hat t akes a l ot mor e ski l l on t he par t of t he bui l der .
Wi t h i nt er nal f i l l et br azi ng, t he t ubes ar e mi t er ed as usual , but
a br ass cont our ed r i ng i s i nser t ed bef or e t he t ubes ar e cl amped
i n t he f i xt ur e. The bui l der t hen heat s up t he whol e j oi nt t i l l
t he br ass can be seen seepi ng f r omt he j oi nt . Gr avi t y i s of t he
ut most i mpor t ance i n t hi s pr ocess. The j oi nt must be hel d so as
t o al l ow t he br ass t o f l ow down and out . The i nt r i gui ng t hi ng
about t hi s t ype of j oi nt i s t hat i t appear s t hat t her e i s not hi ng
hol di ng t he j oi nt t oget her . Of cour se, si nce t he f i l l et i s
smal l er i n di amet er and si nce t her e i s l ess br azi ng mat er i al ,
t hi s j oi nt i s t he weakest of t he l ugl ess j oi nt s.
ill.117: Internal fillet brazing
I NTERNAL- EXTERNAL FI LLET BRAZI NG
Thi s i s an expensi ve way t o do a j oi nt and ver y f ew bui l der s
wi l l go t o t he t r oubl e of usi ng t hi s met hod. The f i r st st ep i s
t o do an i nt er nal f i l l et as above. Then a l ar ge f i l l et i s bui l t
up and f i ni shed as descr i bed at t he t op of page 8- 2.
MITEREDJOINT FINISHEDJOINT
i11.118: Internal-external fillet brazing
RECOMMENDATI ONS AND HI NTS FOR DOI NG LUGLESS BRAZED J OI NTS:
1. For easy cl ean up of f l ux, use Wel co #17 wat er sol ubl e br ass
br azi ng f l ux. Most br ass br azi ng f l uxes ar e not wat er sol ubl e
and must be chi pped of f or sandbl ast ed away. Wel co #17 t akes
at l east a hal f hour of soaki ng i n hot wat er t o di ssol ve
suf f i ci ent l y.
2. Sever al t ypes of br azi ng al l oy can be used. The ol d st andar d
l ow t emper at ur e br ass r od t hat sel l s f or $3. 00 a pound i s
accept abl e. Eut ect i c makes a r at her expensi ve Ni ckel - Br onze
al l oy whi ch wor ks wel l . Al l st at e makes a mi d- pr i ced
Ni ckel - si l ver al l oy whi ch wor ks wel l ( ask f or Al l st at e #11) .
Al l st at e #11 i s t he aut hor ' s f avor i t e; because of i t s
machi ni ng pr oper t i es, i t wi l l not gumup t ool s as much as t he
br ass r od. I t wor k- har dens up t o 200 on t he Br i nel l scal e.
3. I f Wel co #17 i s not avai l abl e, use a st andar d powder ed br azi ng
f l ux. Any of t he above br azi ng r ods can al so be pur chased
wi t h a f l ux coat i ng. Remember , st andar d br azi ng f l ux wi l l
have t o be chi pped away af t er br azi ng. The st eel adj acent t o
t he br azi ng al l oy has been anneal ed and wi l l dent i f chi ppi ng
i s done t oo vi gor ousl y.
4. Chr ome- Mol y t ubi ng i s t he best f or f i l l et br azi ng. I t hol ds
up wel l under t he hi gher t emper at ur es i nvol ved. Al l of t he
bi cycl e f r ame t ubi ng compani es of f er set s of t ubi ng made of
Chr ome- Mol y. Chr ome- Mol y ai r cr af t t ubi ng can be pur chased at
many smal l muni ci pal ai r por t s. I f usi ng ai r cr af t t ubi ng,
di f f er ent wal l t hi cknesses can be speci f i ed. For gener al
pur pose wor k, ask f or . 035" wal l . For heavy dut y wor k, ask
f or . 049" wal l .
For t andembot t omt ubes, ask f or . 065" wal l .
For l i ght wor k usi ng t ubes smal l er t han 1/ 2
"
i n di amet er , ask
f or . 028" wal l . A . 020" wal l can not be r ecommended f or
l ugl ess bui l di ng.
5. I f usi ng a st andar d bi cycl e f r ame t ubi ng ki t t o bui l d a
l ugl ess f r ame, di scar d t he st ock head t ube and obt ai n an
I shi wat a t andemhead t ube or a pi ece of 1- 5/ 16" di amet er
ai r cr af t t ubi ng wi t h a wal l t hi ckness of . 072". A st andar d
head t ube i s much t oo t hi n f or l ugl ess bui l di ng and wi l l
di st or t dr ast i cal l y.
6. Lugl ess bot t ombr acket shel l s ar e cheap and can be pur chased
f r ommost whol esal er s who sel l f r ame suppl i es. I f not
avai l abl e, have a l ocal machi ne shop make one 1. 625" O. D. X
1. 325" I . D. X 2. 717"
l ong ( t ol er ances - pl us or mi nus . 002")
Then t ap i t out af t er i t has been at t ached t o t he seat t ube.
TI G WELDED LUGLESS J OI NTS
Chr ome- Mol y does not al ways have t o be br azed t oget her .
Anot her opt i on i s Gas Tungst en Ar c Wel di ng or GTAW( al so r ef er r ed
t o as Tungst en and I ner t Gas or TI G. ) . TI G wel di ng i s si mi l ar t o
ar c wel di ng i n t hat an el ect r i cal cur r ent i s used t o cr eat e t he
heat . I t i s al so si mi l ar t o Oxy- Acet yl ene i n t hat t he Tungst en
st yl us i s mani pul at ed i n much t he same way as a gas f l ame. The
added benef i t s ar e bei ng abl e t o cont r ol t he st r engt h of t he ar c
wi t h t he f oot and achi evi ng t he necessar y heat i nst ant aneousl y.
Because of t he f oot cont r ol , t he ar c can be ki cked up f ar beyond
t he necessar y heat f or a shor t per i od of t i me. When t he
necessar y t emper at ur e i s achi eved i n a f ew seconds, t he f oot can
be backed of f t o t he wor ki ng t emper at ur e. Si nce t he ar c i s so
hot , l ong pr eheat s ar e not necessar y. The j oi nt can be
compl et el y f i ni shed i n onl y a mi nut e or t wo. Because of t he
gr eat speed i nvol ved, met al onl y cent i met er s away f r omt he j oi nt
i s not even hot . Consequent l y, si nce t he near by met al hasn' t
even become r ed hot , i t does not r each t he "cr i t i cal t emper at ur e. "
( Dependi ng on t he al l oy, t he cr i t i cal t emper at ur e occur s at
appr oxi mat el y 1800 degr ees F. At t hi s t emper at ur e, t he st eel ' s
cr yst al l i ne st r uct ur e i s begi nni ng t o change, whi ch al t er s i t s
st r engt h char act er i st i cs dr ast i cal l y. ) Af t er TI G wel di ng, t he
f r ame can be col d set . When t he f r ame i s i n pr oper al i gnment , a
f ul l heat t r eat ment can be done on t he f r ame. Thi s r el i eves any
st r esses bui l t up i n t he f r ame. Col d set t i ng and heat t r eat i ng
can be done sever al t i mes. ( Heat t r eat i ng can not be done on a
br azed f r ame; t he t emper at ur e necessar y f or t he pr ocess woul d
mel t al l of t he j oi nt s apar t . ) Af t er heat t r eat i ng, t he TI G
wel ded f r ame can be t hor oughl y shot peened. Shot peeni ng not onl y
r el i eves st r esses whi ch may st i l l exi st i n t he f r ame, i t al so
l i t er al l y put s back st r engt h whi ch was l ost f r omhi t t i ng t he
cr i t i cal t emper at ur e. ( Shot peeni ng can' t be done as ef f ect i vel y
on a l ugl ess br azed f r ame; t he shot peeni ng r ui ns t he smoot h
f i ni sh of t he j oi nt . ) I f done pr oper l y, t he TI G wel ded f r ame i s
f ar st r onger t han any of t he ot her met hods descr i bed t hus f ar .
The mai n dr awbacks t o TI G wel di ng ar e: 1) The equi pment necessar y
i s f ar mor e expensi ve t han oxy- acet yl ene. 2) The j oi nt s do not
have a f i ni shed l ook at al l . 3) Few cust omer s r eal i ze t he
benef i t s of a pr oper l y done TI G wel ded j oi nt .
RECOMMENDATI ONS AND HI NTS FOR THE TI G WELDED J OI NT
1. A st andar d Chr ome- Mol y bi cycl e f r ame t ubi ng set can be used.
An except i on i s t he head t ube, whi ch must be r epl aced wi t h a
t hi cker t andemhead t ube or 1- 5/ 16" O. D. X . 072" wal l Chr o- Mo
ai r cr af t t ubi ng.
2. Do not mi x al l oys of st eel i n t he f r ameset . I f 4130 Chr o- Mo
i s used f or t he t ubes, t he bot t ombr acket shel l must al ways be
made of 4130 Chr o- Mo. Such a bot t ombr acket shel l may have t o
be made i f not r eadi l y avai l abl e. ( See specs on page 8- 4. )
be br azed i n pl ace i f
heat t r eat i ng wi l l be
3. Dr opout s, br i dges, and br aze- ons can
heat t r eat i ng wi l l not be done. I f
done, ever yt hi ng must be TI G wel ded.
4. Any heat t r eat i ng shoul d be done
per sonnel and may be qui t e expensi ve.
6. Use onl y Chr o- Mo st eel f i l l er r od
st eel .
5. Shot peeni ng shoul d al so be done by
per sonnel .
by qual i f i ed ai r cr af t
qual i f i ed ai r cr af t
i n TI G wel di ng Chr o- Mo
7. TI G wel ded j oi nt s need vi r t ual l y no cl ean- up because t hey ar e
done i n an envel ope of i ner t gas.
8. I f br azi ng i s t o be done i n t he vi ci ni t y of a TI G wel ded
j oi nt , TI G f i r st and br aze l at er .
9. Pr act i ce ext ensi vel y on pi eces of scr ap bef or e at t empt i ng t o
wel d t hi n- wal l ed t ubi ng.
8- 6
ALUMI NUMLUGLESS J OI NTS
Let ' s be honest . I have dedi cat ed 3 year s of my l i f e t o
wr i t i ng t hi s book about bi cycl e f r amebui l di ng wi t h st eel
component s. I enj oy wor ki ng wi t h st eel and hope i t out l i ves t he
al umi numcr aze. A massi ve chunk of t he wor l d' s bi cycl e i ndust r y
r el i es on st eel f r ames and a maj or move away f r omt hat di r ect i on
coul d be qui t e upset t i ng t o t he i ndust r y. For t hat r eason t he
f ol l owi ng advant ages and di sadvant ages of al umi nummay show some
bi as.
ADVANTAGES OF USI NG ALUMI NUMFRAMES
1. Al umi numdoes not cor r ode t he way st eel does. When
st eel st ar t s t o r ust , i t can event ual l y r ust away i nt o
t hi n ai r , as i s qui t e evi dent on many Wi sconsi n
aut omobi l es. Al umi numdevel ops a t hi n l ayer of
cor r osi on ( al umi numoxi de) on i t s sur f ace and t hat i s
as f ar as i t goes. The onl y way t he cor r osi on can go
deeper on al umi numi s i f t he al umi numoxi de i s pol i shed
and a new l ayer i s al l owed t o devel op.
2. Al umi numf r ames ar e gener al l y l i ght er t han st eel f r ames.
DI SADVANTAGES OF USI NG ALUMI NUMFRAMES
1. An al umi numf r ame can not be r epai r ed as easi l y as a
st eel f r ame. To be r epai r ed pr oper l y, an al umi num
f r ame must be sent back t o t he f act or y wher e i t can be
TI G wel ded and r e- heat - t r eat ed pr oper l y. I n emer gency
si t uat i ons st eel f r ames can be br azed by a smal l
wel di ng shop.
2. Al umi numf r ames need an addi t i onal aci d t r eat ment
bef or e pai nt i ng can be done.
3. Once t he set of "br aze- ons" ar e i n pl ace on an al umi num
f r ame, i t becomes qui t e di f f i cul t t o cust omi ze or
modi f y t he f r ame. A st eel f r ame can be sent t o a l ocal
bui l der f or a compl et e new set of br aze- ons.
4. Al umi numf r ames of t en use over si zed t ubes. Si nce t he
i ndust r y i s set up f or f r ames wi t h 1" and 1- 1/ 8"
di amet er t ubes; f r ont der ai l l eur s, pump cl i ps,
chai nst ay st ops, bot t l e cage cl i ps, and many ot her
accessor i es won' t f i t . Not hi ng st andar d wi l l f i t t hese
"Bl i mps, " AND, si nce t hey ar e made of al umi num, t hey
must go back t o t he f act or y f or modi f i cat i ons.
5. St eel has a t hr eshol d bel ow whi ch f at i gue i s no
pr obl em. Al umi numhas no "saf et y val ve" l i ke t hat .
Why do you t hi nk most al umi numbi kes have st eel f or ks?
8- 7
TIG WELDING OF ALUMINUMPARTS
Wel di ng al umi numcr eat es pr obl ems f or t he wel der . As
ment i oned ear l i er , al umi numwi l l f or man oxi de on t he sur f ace.
The i nt er est i ng t hi ng about al umi num- oxi de i s t hat i t mel t s at
3500 degr ees F, whi l e al umi nummel t s at onl y 1215 degr ees F. When
t he al umi numi s heat ed up t o what i s expect ed t o be a comf or t abl e
wel di ng t emper at ur e, not hi ng seems t o be happeni ng. The j oi nt
get s hot t er and hot t er and st i l l not hi ng happens. Then suddenl y
t he whol e j oi nt pl ops i n a bi g puddl e on t he f l oor and t he pi ece
i s r ui ned. Her e i s what happened: By t he t i me 1215 degr ees had
been r eached, a har d cr ust of al umi num- oxi de had f or med and
encased t he whol e j oi nt ar ea. As t he t emper at ur e i ncr eased, t he
al umi numdi dn' t seemt o mel t when, i n f act , i t was al r eady
mol t en and onl y hel d i t s shape because of t he al umi num- oxi de
cr ust . When 3500 degr ees was f i nal l y achi eved and t he cr ust
f i nal l y mel t ed, t he mol t en Al umi numcoul d no l onger keep i t s f or m
and pl opped on t he f l oor .
The di scr epancy bet ween t he mel t i ng t emper at ur es of al umi num
and al umi num- oxi de i s onl y par t of t he pr obl em. Al umi numi s an
i ncr edi bl y ef f i ci ent conduct or of heat . Because of t hi s, an
oxy- acet yl ene t or ch of t en l acks t he out put t o heat t he j oi nt f or
wel di ng. Consequent l y, when t he j oi nt pl ops on t he f l oor , i t ' s a
r at her l ar ge sect i on of t he j oi nt t hat i s af f ect ed.
To over come t hese pr obl ems i n wel di ng al umi numj oi nt s, t he
pi eces must be TI G wel ded. TI G wel di ng does t wo t hi ngs
si mul t aneousl y: 1) Si nce t he TI G syst emenvel ops t he wel d bead i n
a bubbl e of i ner t gas, al umi num- oxi de can' t f or m. 2) Si nce t he
TI G syst emhas f ar mor e heat i ng capabi l i t i es t han oxy- acet yl ene,
t he ar ea bei ng wel ded can be heat ed t o wel di ng t emper at ur e al most
i nst ant aneousl y, bef or e t he al umi numcan conduct t he heat away.
( The pr oper met hod i s i ni t i al l y t o ki ck t he amps up ver y hi gh
wi t h t he f oot pedal and t hen t o dr op qui ckl y back t o t he
necessar y t emper at ur e. Thi s del i ver s near l y 7000 degr ees F f or a
f ew seconds. )
TI G WELDED LUGLESS ALUMI NUMJ OI NT ( SI MPLE)
The al umi numj oi nt i s mi t er ed j ust l i ke any ot her j oi nt . A
bead i s t hen l ai d al l ar ound t he ci r cumf er ence of t he j oi nt . An
exper i enced t echni ci an can do t hi s i n 45 t o 90 seconds. The
j oi nt i s done. Ther e i s no cl ean- up. The j oi nt i s now r eady f or
heat t r eat i ng.
8- 8
BEAD BUI LD- UP FI NI SHED J OI NT
MI TERED J OI NT FI NI SHED J OI NT
ill,121: TIG welded joint- aluminum(simple)
TIG WELDEDLUGLESS ALUMINUMJOINT(BUILTUP)
The bui l t - up al umi numj oi nt i s a mor e at t r act i ve j oi nt . I t
has successi ve l ayer s of wel d beads bui l t up t o f or ma l ar ge
f i l l et . When t he f i l l et i s compl et ed, i t i s cl eaned and smoot hed
out . The r esul t i s a j oi nt si mi l ar t o t he br ass br azed f i l l et i n
appear ance. The mai n pr obl emwi t h t he bui l t - up j oi nt i s gr eat er
di st or t i on due t o mor e heat f or a l onger per i od of t i me.
Addi t i onal di st or t i on i s caused each t i me a successi ve bead of
al umi numi s added.
ill.122: TIGweldedjoint-aluminum(built-up)
I hope t hi s i nf or mat i on on al umi numl ugl ess const r uct i on
gi ves you pl ent y of ammuni t i on when cust omer s appr oach you on t he
mer i t s of al umi numbi cycl e f r ames.
8- 9
.J24 M!Cw O O] I
MI G WELDED LUGLESS STEEL J OI NTS
Anot her met hod of wel di ng st eel qui ckl y and ef f i ci ent l y i s t o
use Gas Met al Ar c Wel di ng ( GMAW) al so known as Met al and I ner t
Gas ( MI G) . MI G wel di ng al so uses a bubbl e of i ner t gas t o pr event
oxi dat i on. I t i s as f ast as TI G, but , due t o t he si ze of t he gun
and t he l ack of a f oot cont r ol , i t does not pr oduce as del i cat e a
bead as TI G.
Anywher e a MI G bead i s
and bul ky. For t hi s r eason,
bead out wi t h a gr i nder or
pl ace. Bel ow ar e di agr ams
pr oduced, MI G wel ded f r ame
pr oduced, i t l ooks r at her unsi ght l y
i t i s desi r abl e ei t her t o smoot h t he
pl ace t he bead i n an i nconspi cuous
of a popul ar , l ow cost , commer ci al l y
MA CH O AMF! C
F! ! H O} !
B-JD
FRAMEBUI LDER' S CHECKLI ST FOR LUGLESS CONSTRUCTI ON
The f ol l owi ng i s a det ai l ed st ep- by- st ep checkl i st t o be used
by t he f r amebui l der who i s f ami l i ar wi t h t he checkl i st i n Sect i on
3 of t hi s book and i s r eady t o at t empt a l ugl ess f r ame.
Si nce t her e ar e many si mi l ar i t i es bet ween l ugged const r uct i on
and l ugl ess const r uct i on, t hi s l i st i s t o be used i n conj unct i on
wi t h t he checkl i st i n Sect i on 3. Thi s new checkl i st wi l l have
t he bui l der go t o t he ear l i er checkl i st and execut e desi gnat ed
st eps t her e. When t hose st eps ar e compl et ed, t he bui l der wi l l
t hen r et ur n t o t hi s checkl i st and execut e t he st eps i n l ugl ess
const r uct i on whi ch ar e di f f er ent f r oml ugged const r uct i on. The
bui l der wi l l be const ant l y r ef er r ed back and f or t h t hr ough t he
t wo checkl i st s whi l e bui l di ng a l ugl ess f r ame.
I . THE DRAWI NG ( The cr own must be pur chased by t hi s t i me. )
1. Go t o t he dr awi ng sect i on on page 3- 3 and do st eps 1 t hr ough
10. Af t er compl et i ng t hose st eps, r et ur n her e.
2. Si nce t he l ugl ess head t ube i s 1- 5/ 16" i n di amet er , dr aw a
pai r of l i nes par al l el t o t he head t ube cent er l i ne wi t h one
l i ne 21/ 64" on one si de of t he cent er l i ne and t he ot her 21/ 64"
on t he ot her si de of t he cent er l i ne. The head t ube has j ust
been dr awn
3. Go back t o page 3- 4 and do st eps 12 t hr ough 16. Af t er
compl et i ng t hose st eps, r et ur n her e.
4. Si nce t her e ar e no l ugs, t he HT/ DT TUBE I NTERCEPT POI NT can be
det er mi ned ar bi t r ar i l y by t he bui l der . I n l ugl ess bui l di ng,
1cmi s a good HT/ DT I NTERCEPT POI NT. Thi s wi l l al l ow enough
ar ea t o bui l d a f i l l et . Now move t o t he back edge of t he head
t ube and measur e up f r omt he pr evi ous l i ne a di st ance of 1cm.
t o t he HT/ DT I NTERCEPT POI NT. Make a mar k at t hat poi nt .
5. Make a deci si on:
A. I f t he f r ame wi l l have a 1- 1/ 8" di amet er down t ube, go
t o page 3- 5 and do st eps 18 t hr ough 22. Af t er
compl et i ng t hose st eps, r et ur n her e.
B. I f t he f r ame wi l l have a down t ube wi t h a non- st andar d
di amet er , make a new f r amebui l der ' s st r ai ght edge t o
mat ch t he di amet er of t he down t ube t o be used. Now go
t o page 3- 5 and do st eps 18 t hr ough 22. Af t er
compl et i ng t hose st eps, r et ur n her e.
8- 11
1. GENERAL PREPARATI ON ( The t ube set , bot t ombr acket shel l , and
' cor k cr own shoul d have been pur chased by now. )
. . Go t o page 3- 7 and execut e st ep 3. Af t er compl et i ng t hat
st ep, r et ur n her e.
t o page 3- 7 and execut e st eps 5 t hr ough 10. Af t er
compl et i ng t hose st eps, r et ur n her e.
3. Mi t er t he end of t he seat t ube wher e i t f i t s agai nst t he
bot t ombr acket shel l . I f t he seat t ube i s but t ed, t he but t ed
end goes agai nst t he bot t ombr acket shel l . The best way t o
f i nd t he but t ed end i s t o f i nd out whi ch end a 27. 2mmseat
post wi l l easi l y f i t i nt o. The ot her end i s t he but t ed end.
To avoi d conf usi on, wr ap t he non- but t ed end wi t h a r i ng of
maski ng t ape. The mi t er can be r oughed i n wi t h t he gr i ndi ng
wheel and cl eaned up wi t h a f i l e. The mi t er must be checked
f or squar eness wi t h a machi ni st ' s squar e ( f i g. 190) . I t must
al so be checked f or gaps by hol di ng i t agai nst t he bot t om
br acket shel l and l ooki ng f or l i ght bet ween t he t wo pi eces
( f i g. 191) . Dur i ng t hi s pr ocedur e, t he t ube shoul d be hel d i n
a Par k cl amp or a pai r of f r amebui l der ' s t ube cl amps. ( See
Fi xt ur es. ) ( See f i gs. 14 & 15)
4. Mi t er t he end of t he down t ube wher e i t hi t s t he backsi de of
t he head t ube. ( I t wi l l be mi t er ed t o an angl e of 56 t o 63
degr ees. ) For Reynol ds, mi t er t he shor t but t now. For
Col umbus, make sur e t o have t he cor r ect A, B, or C set . The
mi t er can be r oughed i n wi t h t he gr i ndi ng wheel and f i ni shed
of f wi t h an 8" hal f r ound f i l e. Agai n, t he t ube shoul d be
hel d i n a Par k cl amp or t ubi ng bl ocks. The mi t er can be
checked wi t h t he t hr ee devi ces t hat f ol l ow:
A. The angl e of t he mi t er must be checked wi t h a bevel
pr ot r act or f r equent l y dur i ng t he mi t er i ng pr ocess. The
cor r ect angl e may be t aken f r omt he dr awi ng wi t h t he
bevel pr ot r act or .
B. The pr oper f i t must be checked wi t h a pi ece of head
t ube. The head t ube must nest l e i nt o t he mi t er wi t h an
absol ut e mi ni mumof l i ght showi ng t hr ough bet ween t he
t wo pi eces.
C. To see i f t he mi t er f al l s di r ect l y al ong t he cent er l i ne
of t he down t ube, a machi ni st ' s squar e can be l ai d
acr oss t he t wo peaks of t he mi t er . Bot h shoul d be at
t he same hei ght . ( f i gs. 13 t o 20. )
5. Mi t er t he shor t but t ed end of t he t op t ube wher e i t meet s t he
backsi de of t he head t ube. I f usi ng non- but t ed t ubi ng, ei t her
end can be mi t er ed. Agai n, t he angl e can be t aken di r ect l y
f r omt he dr awi ng. Asi de f r omt he angl e necessar y, t he
pr ocedur e i s i dent i cal t o t hat used f or mi t er i ng t he down
t ube. To avoi d conf usi on l at er , i t i s ver y i mpor t ant t o wr ap
a r i ng of maski ng t ape ar ound t hi s f i r st end.
I I I . THE FRONT TRI ANGLE - At t hi s poi nt , no br azi ng has been done
and onl y one end of each t ube has been wor ked wi t h. Mat er i al s on
hand at t hi s t i me shoul d i ncl ude t he pr epped t ube set , 1 pound of
br azi ng r od as descr i bed on page 8- 3, Wel co #17 or ot her br ass
br azi ng f l ux, medi umemer y cl ot h and sandi ng bel t s f or t he
dynabr ade sander .
1. Dr i l l a 1/ 2" ai r expansi on hol e i n t he bot t ombr acket shel l .
I t shoul d be l ocat ed mi dway bet ween t he t wo f aces of t he
shel l . ( f i g. 192)
8- 13
193
194

2. Cl ean t he bot t ombr acket shel l and mi t er ed end of t he seat

t ube f or br azi ng. Cl eanl i ness i s not as cr i t i cal as i t i s i n
si l ver br azi ng so cl ean up can be done wi t h a st r i p of emer y
cl ot h.
3. Ver y l i t t l e f i xt ur i ng i s necessar y f or l ugl ess j oi nt s. Cl amp
t he seat t ube i n t he Par k cl amp wi t h t he mi t er poi nt i ng
st r ai ght up i n t he ai r .
4. Spr ead a gener ous amount of f l ux ar ound t he mi t er ed end of t he
t ube.
5. Spr ead a gener ous amount of br ass br azi ng f l ux on t he bot t om
br acket shel l ar ound t he ai r expansi on hol e.
6. Car ef ul l y set t he l ugl ess bot t ombr acket shel l i nt o t he mi t er
of t he seat t ube so t hat t he ai r expansi on hol e vent s i nt o t he
seat t ube.
7. Wi t h a r ul er t hat measur es i n i ncr ement s of . 5mm, see t hat t he
bot t ombr acket shel l over hangs t he same amount on each si de of
t he seat t ube. Measur e on t he l ef t ( f i g. 193) . Then measur e
on t he r i ght ( f i g. 194) .
8. Whi l e t he seat t ube/ bot t ombr acket shel l i s si t t i ng
upsi de down, t ack t he j oi nt wi t h t he br azi ng al l oy. ( f i g. 195)
9. Af t er t he j oi nt i s t acked, f l i p t he seat t ube r i ght si de up
and cont i nue br azi ng. I t ' s a good i dea t o have t he t ube
mount ed onl y l i ght l y i n t he cl amp and have t he cl amp f ast ened
onl y l i ght l y i n t he st and. That way, t he j oi nt can be easi l y
t wi st ed t o any wor ki ng angl e wi t h onl y one hand. ( Car ef ul
195 196
wher e you gr ab, t hi ngs ar e goi ng t o be hot ! ) As br azi ng
cont i nues, "t i nni ng" shoul d be done f i r st . Ti nni ng i s wher e a
smal l amount of br azi ng al l oy i s appl i ed al l of t he way ar ound
t he j oi nt . Thi s assur es t hat t he br azi ng al l oy wi l l be
pr esent al l of t he way t o t he cr ot ch of t he j oi nt . Af t er
t i nni ng, bui l d f i l l et s onl y on t he si des of t he j oi nt . I t i s
i mpor t ant not t o bui l d f i l l et s on t he f r ont or back of t he
j oi nt because t he chai nst ays and down t ube must be abl e t o
bot t omout agai nst t he bot t ombr acket shel l when t hey ar e
mi t er ed. A f i l l et at t he f r ont or back of t he j oi nt wi l l onl y
have t o be gr ound away l at er . ( f i g. 196)
10. Af t er t he j oi nt has cool ed suf f i ci ent l y, t he f l ux can be
cl eaned of f . I f usi ng Wel co #17 wat er sol ubl e br ass br azi ng
f l ux, soak t he j oi nt i n ext r emel y hot wat er f or at l east a
hal f hour . Al t hough Wel co #17 i s wat er sol ubl e, i t does not
wor k as wel l as si l ver sol der f l ux and may have t o be scr aped
some as wel l . Do not scr ape f l ux wi t h t he f i nger nai l s! I t i s
as shar p as gl ass and wi l l cut ski n r eadi l y. I f usi ng a
st andar d br ass br azi ng f l ux, soaki ng i n wat er wi l l be of no
use. I n t hi s case, t he f l ux must be r emoved by f i l i ng and
chi ppi ng. ( Use a f i l e t hat i s i n bad shape al r eady as f i l i ng
on f l ux wi l l r ui n a good f i l e. ) I t i s ver y i mpor t ant not t o
chi p t he f l ux t oo har d as t he st eel cl ose t o t he j oi nt has
been sof t ened by t he heat of br azi ng. Vi gor ous chi ppi ng coul d
put many unsi ght l y peen mar ks i n t he st eel t ubi ng whi ch woul d
make t he f r ame unsound. When f i l i ng f l ux away, i t i s
i mpor t ant not t o r emove st eel . Removi ng any st eel coul d cause
under cut t i ng whi ch woul d al so cause t he f r ame t o be unsound.
Under cut t i ng wi l l become i nt ensel y vi si bl e af t er pai nt i ng.
I l l ust r at i on 125 shows sever e under cut t i ng.
8- 15
PROPERl Y DONE J OI NT BADLY UNDERCUT J OI NT
i l l . 125: Under cut t i ng
11. Af t er al l of t he f l ux has been cl eaned, t he bot t ombr acket
shel l must be t apped and f aced. I f t he shel l has been
pr e- t apped, det er mi ne whi ch si de i s t apped wi t h a Br i t i sh l ef t
hand t hr ead and st amp an L on t hat si de of t he shel l so as not
t o become conf used as t o whi ch si de i s r i ght or l ef t l at er on.
I f t he shel l has not been pr e- t apped, si mpl y choose a si de and
st amp t he L i n t he si de of t he shel l . Bef or e st ampi ng l et t er s
or number s i n t he bot t ombr acket shel l , al ways scr ew i n a
bear i ng cup so t he shel l does not def or mf r omt he f or ce of t he
bl ow ( f i g. 197) . When t he shel l has been pr oper l y mar ked t o
show l ef t f r omr i ght , go t o page 3- 15 and do st eps 7 t hr ough
9. Af t er compl et i ng t hose st eps, r et ur n her e.
8- 16
12. Wor k can now begi n on t he bot t omhead j oi nt . Wi t h a j ewel er ' s
f i l e mar k t he HT/ DT I NTERCEPT POI NT on one si de of t he head
t ube. ( 1cmi s r ecommended) As soon as t hi s poi nt i s mar ked,
t hi s l ocat es t he backsi de and t he bot t omof t he head t ube.
13. Wi t h V- bl ocks and a machi ni st ' s squar e, pl ace t he headt ube
di r ect l y over i t s cor r ect pl ace on t he dr awi ng. Tr ansf er t he
cent er poi nt s of t he down and t op t ubes up t o t he head t ube and
mar k t hose poi nt s. Ther e shoul d now be t hr ee mar ks i n a l i ne,
t he HT/ DT POI NT, t he l ocat i on of t he down t ube ai r expansi on
hol e, and t he l ocat i on of t he t op t ube ai r expansi on hol e.
14. Dr i l l bot h ai r expansi on hol es t o a di amet er of 1/ 2".
( Remember - huge ai r expansi on hol es! ) Fi gur e 198 shows t he
ai r expansi on hol es and t he HT/ DT I NTERCEPT.
5. Cl ean t he mi t er ed end of t he down t ube f or br azi ng. Remember ,
cl eanl i ness i s not as cr i t i cal as wi t h si l ver sol der .
Emer y cl ot h wi l l be suf f i ci ent .
16. Appl y f l ux
17. Mount t he down t ube i n t he Par k cl amp so t hat i t poi nt s up i n
t he ai r at about a 60 degr ee angl e. ( Agai n, j i ggi ng i n
l ugl ess bui l di ng i s si mpl e and i n some cases non- exi st ent . )
18. Cl ean and f l ux t he pr oper end of t he head t ube. ( Remember , i t
i s t he end wi t h t he f i l e mar k. )
19. Sl i de a 1" di amet er bar i nt o t he head t ube t o be used as a
count er bal ance whi l e t he j oi nt i s bei ng t acked ( f i g. 199) . By
posi t i oni ng t hi s bar cor r ect l y, t he headt ube wi l l bal ance ver y
neat l y i n t he cr ot ch of t he mi t er .
20. Pl ace t he head t ube i nt o t he mi t er so t he ai r expansi on hol e
vent s i nt o t he down t ube and t he mar k f or t he HT/ DT POI NT i s
f l ush wi t h t he bot t omsi de of t he down t ube ( Fi g. 200)
( IMPORTANT: DON'TDO THE ANGLE BACKWARDS!)
21. Tack t he si des of t he j oi nt and r emove t he 1" st eel bar .
2. Af t er t he j oi nt has cool ed some, el evat e i t over t he dr awi ng
wi t h V- bl ocks and a machi ni st ' s squar e t o see how t he angl e of
t he j oi nt compar es t o t he dr awi ng ( f i g. 201) .
JJJ.J26 C I Oh IO I I
Bu Of Ih
f II
c
Bu Of Ih
f II
O c
23. At t hi s poi nt , t he j oi nt has onl y been t acked. I f t he j oi nt i s
of f i t can be cor r ect ed by st r at egi cal l y appl yi ng heat whi l e
br azi ng t he r est of t he f i l l et . Put t he pi ece back i n t he
st and and bui l d t he f i l l et as per t he hi nt s i n i l l ust r at i on
126.
Don' t f or get , t hi s j oi nt i s t he most i mpor t ant one i n t he
whol e f r ame. I f t hi s one i s i ncor r ect , t he whol e f r ont end
geomet r y wi l l be of f . For t hat r eason, t hi s j oi nt shoul d be
done car ef ul l y and shoul d be checked agai nst t he dr awi ng 2 or
3 t i mes dur i ng br azi ng t o see t hat t he angl e i s pr eser ved
whi l e t he f i l l et i s bei ng bui l t . Wi t h pr act i ce, i t shoul d be
possi bl e t o br aze a bot t omhead j oi nt wi t h a mi ni mumof col d
set t i ng.
24. When a f i l l et of t he desi r ed si ze has been at t ai ned ( a smal l er
r adi us f i l l et wi l l cause l ess heat di st or t i on but a l ar ger one
i s st r onger and easi er t o cl ean up cosmet i cal l y) , check t he
angl e agai nst t he dr awi ng agai n. I f col d set t i ng i s
necessar y, sl i de t he 1" bar i nt o t he head t ube, l ay t he head
t ube on t he f l oor . Put a f oot on t he 1" bar , and ei t her l i f t
on t he down t ube t o l essen t he angl e of t he j oi nt or push down
on t he down t ube t o i ncr ease t he angl e of t he j oi nt ( f i g.
202) . Al ways f i ni sh a col d set t i ng sessi on by checki ng t he
angl e of t he j oi nt agai nst t he dr awi ng on t he sur f ace t abl e.
( The use of a down t ube pr ot ect or sheat h woul d be a good i dea
dur i ng t hi s pr ocedur e. )
8- 19
25. El evat e t he down t ube/ head t ube assembl y over t he dr awi ng wi t h
V- bl ocks and machi ni st ' s squar e.
26. Af t er maki ng sur e t he t ubes ar e di r ect l y above t hei r
count er par t s on t he dr awi ng, put t he machi ni st ' s squar e
agai nst t he non- but t ed end of t he down t ube and mar k t he
over al l l engt h of t he down t ube on t he dr awi ng wi t h a penci l
( f i g. 203) . Thi s may be accur at el y done by usi ng t he
machi ni st ' s squar e t o t r ansf er t he down t ube l engt h down t o
t he dr awi ng. Measur e t he di st ance f r omt he mar k j ust made on
t he dr awi ng t o t he poi nt on t he dr awi ng wher e t he cr ot ch of
t he down t ube mi t er wi l l hi t t he bot t ombr acket shel l ( f i g.
204) . Take t he measur ement j ust made and l ay i t out al ong t he
l ef t and r i ght si des of t he down t ube comi ng up f r omt he
non- but t ed end ( f i g. 205) . The down t ube shoul d now be mar ked
wher e t he cr ot ch of t he mi t er wi l l l i e ( f i g. 206) .
27. Cut t he down t ube of f 15mml onger t han t he mar ks j ust made
i ndi cat e.
28. Rough t he mi t er i n on t he gr i nder ( f i g. 207) . Do not go
beyond t he t wo mar ks. I n f act , i t ' s a good i dea t o l eave t he
down t ube 1 or 2mmt oo l ong at t hi s poi nt ( f i g. 208) .
8- 21
29. Fi ni sh mi t er i ng can be done wi t h a 10" hal f r ound f i l e. A
10" wi l l most cl osel y mat ch t he r adi us of t he bot t ombr acket
shel l . Gr eat car e must be t aken t o have t he mi t er l i e
per pendi cul ar t o t he pl ane of t he head t ube. I n most smal l
wor kshops, t hi s can onl y be done by eyebal l . Use an ext r a bot t om
br acket shel l t o l ay i nt o t he cr ot ch of t he mi t er and si ght
t owar d t he head t ube. As i n t he ear l i er mi t er s, check f or gaps
of l i ght i n t he mi t er and check t o see t hat t he mi t er i s squar e
wi t h t he t ube.
30. El evat e t he DT/ HT above t he dr awi ng agai n. The l engt h of t he
down t ube can be checked wi t h t he machi ni st ' s squar e now ( f i g.
209) .
31. El evat e t he seat t ube and bot t ombr acket above t he dr awi ng.
At t hi s poi nt t he seat t ube must be cant ed backwar d ( f i g. 210)
because t he second par t of t he mi t er at t he base of t he down
t ube has not been made yet .
8- 22
Si nce t he f r ameset pr obabl y has t hr ee di f f er ent si zed
t ubes ( 1- 1/ 8" seat t ube, 1- 1/ 4" down t ube, 1- 5/ 16" head t ube) ,
i t i s ext r emel y i mpor t ant t o have t he cor r ect bui l d- up under
t he V- bl ocks t hat ar e under each t ube. Thi s way, al l t he
t ubes wi l l have t he same l evel cent er poi nt s ( CP) . ( I f t her e i s
conf usi on as t o how t o f i nd t he CP of t ubes, see pages 9- 19
t hr ough 9- 22 of t he pr eci si on measur i ng sect i on. ) Fi gur e 211
shows t hr ee di amet er s of t ubi ng bui l t up t o have t he same CP.
To obt ai n t he same CP f or al l t ubes, t ake a hei ght
measur ement f or t he l ar gest di amet er t ube as i t l i es i n t he
V- bl ocks. Subt r act t he r adi us of t hat t ube f r omt hat
measur ement . Thi s wi l l be t he CP of t hat t ube. The ot her of
t he smal l er t ubes shoul d have t he same CP as t he l ar gest t ube.
Take t he hei ght measur ement of one of t he smal l er t ubes and
subt r act t he r adi us; t hat wi l l gi ve t he hei ght of t hat t ube' s
CP. Of cour se, t hat smal l er t ube wi l l have a l ower CP t han
t he l ar gest t ube. To get t he same CP f or bot h t ubes, bui l d up
shi ms under t he smal l er t ube t i l l t he hei ght r eadi ng mi nus t he
r adi us has t he same val ue as t hat of t he l ar gest t ube. Do
t hi s f or al l t ubes whi l e wor ki ng on t he sur f ace t abl e. A CP
of 50mmf or al l t ubes i s a comf or t abl e wor ki ng hei ght .
32. The second par t of t he mi t er at t he bot t ombr acket end of t he
down t ube must be made now. Thi s i s a t r i al - and- er r or
pr ocedur e. Sl owl y st ar t r emovi ng met al f or t hi s mi t er unt i l
t he head t ube, down t ube, seat t ube, and bot t ombr acket shel l
can al l be pl aced above t he dr awi ng wi t hout havi ng gaps
bet ween t he down t ube and t he bot t ombr acket shel l . Thi s i s
pr obabl y t he most di f i cul t j oi nt t o do i n f r amebui l di ng.
Don' t be upset i f t he f i r st t r y doesn' t come out r i ght ; The
f r ame wi l l j ust have t o be a coupl e of mi l l i met er s shor t er
t han t he dr awi ng. Fi gur es 212 &, 213 show t he f i ni shed mi t er .
8- 23
212
33. An ai r expansi on hol e must be dr i l l ed i nt o t he bot t ombr acket
shel l so t hat t he down t ube wi l l vent i nt o i t . Gr eat car e
must be t aken t o dr i l l t he hol e i n t he cor r ect pl ace. At t hi s
poi nt , t he unt r ai ned eye woul d per cei ve t hat t he down
t ube/ bot t ombr acket i s a r ever si bl e pi ece. WRONG! Remember t he
L st amped i nt o t he bot t ombr acket shel l ? Put your r i ght hand
on t he f ace of t he shel l wher e t he L i s st amped. Put your l ef t
hand on t he f ace of t he shel l t hat has not been mar ked. Now
put your nose i n t he hol e at t he t op end of t he seat t ube.
You ar e now l ooki ng di r ect l y at t he l ocat i on wher e t he ai r
expansi on hol e shoul d be dr i l l ed. I f you mi scal cul at e af t er
t hose di r ect i ons, you deser ve t o have a 1/ 2" hol e i n t he back
si de of your bot t ombr acket shel l !
34. Dr i l l hol e.
35. Cl ean up bot t ombr acket shel l and end of down t ube f or
br azi ng.
36. Appl y f l ux t o bot h sur f aces.
37. Lay t he t ubes i nt o t he V- bl ocks agai n and r e- al i gn al l t ubes
wi t h t he dr awi ng usi ng t he machi ni st ' s squar e.
38. Lay a heavy wei ght acr oss t he head t ube and seat t ube. Thi s
heavy wei ght wi l l hol d t he seat and head t ubes t i ght agai nst
t he sur f ace t abl e and keep t hemi n t he same pl ane whi l e t he
j oi nt i s bei ng t acked. Not e heavy bar st ock of al umi numi n
f i g. 214.
8- 24
39. Car ef ul l y sl i de a pi ece of sheet met al bet ween t he bot t om
br acket and t he sur f ace t abl e ( f i g. 214) . Thi s wi l l pr ot ect
t he sur f ace t abl e f r omany f l ux or br azi ng mat er i al t hat dr ops
of f t he j oi nt dur i ng t acki ng. I f t he f r ame t ubes have a CP of
about 50mmor mor e, t he pi ece of sheet met al wi l l sl i de i n
easi l y. I f t he bot t ombr acket i s t oo cl ose t o t he sur f ace
t abl e, go back and shi mup t he V- bl ocks t o gai n mor e hei ght .
40. Doubl e check t o see t hat t he t ubes ar e t r ue wi t h t he l i nes on
t he dr awi ng.
41. Doubl e check t o see t hat t he down t ube i s bot t omi ng out
agai nst t he bot t ombr acket shel l .
42. Tack t he j oi nt i n t hr ee pl aces ( f i g. 215) .
43. Af t er t acki ng has been done, t he t ubes can be l i f t ed f r omt he
dr awi ng and t he r est of t he f i l l et can be bui l t up i n t he Par k
st and ( f i g. 216) . As bef or e, car ef ul appl i cat i on of heat can
be used t o cont r ol heat di st or t i on. Remember , t he t ubes pul l
t owar d t he f i l l et bei ng bui l t up.
8- 25
44. Af t er t he j oi nt has cool ed suf f i ci ent l y, al l f l ux shoul d be
cl eaned of f .
45. Tap and f ace t he bot t ombr acket shel l agai n. Yes - Agai n!
Down t ube def l ect i on must be checked wi t h t he bot t ombr acket
mi ke. Due t o t he i ncr eased t emper at ur e of l ugl ess wor k, t he
bot t ombr acket f aces ar e compl et el y out of par al l el by now.
Ear l i er i n t hi s sect i on a 69mmbot t ombr acket shel l was
r ecommended. The ext r a mi l l i met er al l ows t he shel l t o be
f aced sever al t i mes wi t hout goi ng under si zed. Leave
Campagnol o gui des 724/ 1 and 724/ 2 i nsi de t he bot t ombr acket
shel l dur i ng col d set t i ng. Thi s wi l l hel p el i mi nat e
di st or t i on t o t he shel l .
46. Check t he down t ube f or def l ect i on t o t he l ef t or t he r i ght
( f i gs. 46 & 47) .
48. I f t he down t ube has def l ect ed i n ei t her di r ect i on, cl amp t he
f aces of t he bot t ombr acket shel l i n t he sof t j aws of t he vi se
and pul l i n t he di r ect i on necessar y t o el i mi nat e t he
def l ect i on. Check f or def l ect i on agai n and col dset mor e i f
necessar y. Tr y not t o over shoot t he mar k; each t i me col d
set t i ng i s done, wor k har deni ng of t he met al occur s. Too much
wor k har deni ng means br i t t l eness.
49. Lay t he f r ame i n t he V- bl ocks agai n and check t o see i f t he
angl es of t he f r ame mat ch t he dr awi ng. The angl e wher e t he
down t ube and seat t ube meet t he bot t ombr acket shel l may have
t o be col dset t o mat ch t he dr awi ng. I f col d set t i ng i s
necessar y, sl i de a 1" st eel bar down t he seat t ube and l ay t he
seat t ube on t he f l oor . St ep on t he seat t ube and gr asp t he
head t ube wi t h bot h hands ( f i g. 217) . Push downwar d t o make
t he angl e smal l er . Pul l upwar ds t o make t he angl e l ar ger .
Check t hi s sever al t i mes agai nst t he dr awi ng whi l e col d-
set t i ng so as t o be assur ed of achi evi ng t he cor r ect angl e.
The bot t omhead j oi nt shoul d have been pr oper l y col dset
ear l i er and shoul d not be t amper ed wi t h at t hi s t i me.
50. Lay t he f r ame i n t he V- bl ocks and si t uat e i t di r ect l y above
t he dr awi ng usi ng t he machi ni st ' s squar e.
51. Usi ng t he machi ni st ' s squar e, l ocat e t he poi nt s wher e t he t op
t ube hi t s t he backsi de of t he head t ube. Make a mar k t her e
wi t h a t r i angul ar j ewel er ' s f i l e. ( See Fi g. 64)
52. Usi ng a machi ni st ' s squar e, l ocat e t he poi nt s wher e t he t op
t ube hi t s t he f r ont of t he seat t ube. Make a mar k t her e wi t h
a f i l e ( f i g. 66) .
52. Usi ng t he machi ni st ' s squar e, l ocat e t he posi t i on f or t he ai r
expansi on hol e wher e i t vent s i nt o t he t op t ube. Make a mar k
t her e and dr i l l t he ai r expansi on hol e at t hat poi nt ( f i g.
66) . ( The ai r expensi on hol e i n t he head t ube shoul d have been
dr i l l ed ear l i er ; i f i t hasn' t been dr i l l ed, do so now. )
53. Use emer y cl ot h t o cl ean t he head t ube and seat t ube f or
br azi ng.
54. Cl amp t he f r ame i n t he Par k cl amp unt i l i t i s needed agai n.
55. Doubl e check t o see t hat a r i ng of maski ng t ape has been put
ar ound t he t op t ube near t he f i r st end t hat was mi t er ed.
8- 27
56. Go t o t he dr awi ng and measur e t he di st ance f r omt he poi nt
wher e t he t op of t he t op t ube hi t s t he back si de of t he head
t ube t o t he poi nt wher e t he t op of t he t op t ube hi t s t he f r ont
of t he seat t ube.
57. Go t o page 3- 23 and execut e st eps 57 t hr ough 62. ( Ther e wi l l
be some mi nor di scr epanci es wi t h t he number i ng of cer t ai n
st eps, but t he cr azy sent ence above shoul d make i t l ess
conf usi ng. ) Af t er compl et i ng t hose st eps, r et ur n her e.
58. When t he j oi nt i s mi t er ed t o t he pr oper f i t , sand t he ends of
t he t op t ube wi t h emer y cl ot h t o pr epar e i t f or br azi ng.
59. Set t he t op t ube i n pl ace bet ween t he head t ube and t he seat
t ube. The t op t ube wi l l not want t o st ay i n pl ace. To make
i t st ay i n pl ace i nst al l a modi f i ed C- cl amp #1 ar ound t he head
t ube r i ght above t he t op t ube. I nst al l anot her modi f i ed
C- cl amp #1 ar ound t he seat t ube r i ght bel ow t he t op t ube.
These t wo cl amps wi l l pr event t he t op t ube f r omcr eepi ng down
i n f r ont and cr eepi ng up i n back. The modi f i ed C- cl amps can be
seen i n f i gur e 218.
60. I nst al l a modi f i ed bar cl amp t o push t he head t ube and seat
t ube t oget her ( f i g. 218) .
61. Appl y a gener ous amount of f l ux t o t he j oi nt s at each end of
t he t op t ube.
62. Tack t he t op t ube t o t he head t ube i n t wo pl aces.
63. Tack t he t op t ube t o t he seat t ube i n t wo pl aces.
64. Remove t he modi f i ed bar cl amp and bot h modi f i ed C- cl amps.
65. Ti nni ng shoul d be done t o t he head t ube/ t op t ube j oi nt bef or e
bui l di ng t he r est of t he f i l l et .
66. Fi ni sh bui l di ng t he br azed f i l l et wher e t he head t ube and t op
t ube meet .
67. Ti nni ng shoul d be done t o t he seat t ube/ t op t ube j oi nt bef or e
bui l di ng t he r est of t he f i l l et .
68. Fi ni sh bui l di ng t he br azed f i l l et wher e t he seat t ube and t op
t ube meet .
69. Af t er t he j oi nt s have cool ed suf f i ci ent l y, al l f l ux must be
r emoved as descr i bed ear l i er .
70. Now cl ean- up must be done on t he bot t omhead j oi nt , t op head
j oi nt , and seat cl ust er j oi nt . The f i r st st ep i s t o t ake t he
di e gr i nder wi t h an abr asi ve cut - of f wheel mount ed i n i t and
gent l y sweep over t he br ass f i l l et s ( f i g. 219) . Thi s wi l l t ake
down t he mor e not i ceabl e hi gh spot s. GRI ND AWAY AT THE FI LLET
MATERI AL ONLY! ! Any gr i ndi ng i nt o t he st eel wi l l cause ver y
unsi ght l y under cut t i ng. I t i s easy t o t el l when t he gr i nder
hi t s st eel ; t he st eel t hr ows spar ks - t he br ass won' t .
71. Now t he t hr ee j oi nt s can be smoot hed out wi t h a Dynabr ade
sander ( f i g. 220) . ( I f you don' t have a Dynabr ade sander , see
i f you can bor r ow or r ent one. ) When sandi ng wi t h t he
Dynabr ade, use a 60 gr i t bel t and expect t o wear out t wo bel t s
f or each j oi nt . Do 95%of t he sandi ng on t he br ass f i l l et .
The r emai ni ng 5%of t he sandi ng can be used t o smoot h out t he
br ass sur f ace as i t meet s t he st eel . Her e agai n, under cut t i ng
i s a def i ni t e pr obl emand must be avoi ded. Under cut t i ng i s
f r ust r at i ng because i t won' t show up unt i l t he f r ame i s
pai nt ed.
8- 29
72. Fi nal sandi ng can be done wi t h st r i ps of emer y cl ot h. Emer y
cl ot h can be pur chased i n 100 f oot r ol l s wi t h a wi dt h of 1".
Use 100 gr i t emer y cl ot h st r i ps t or n t o l engt hs of about 15".
Pul l t he st r i p wi t h one hand whi l e hol di ng i t down t i ght l y
wi t h t he t humb of t he ot her hand ( f i g. 221) . Thi s i s when you
cut t he web of ski n bet ween t he t humb and f or ef i nger and i t
r eal l y hur t s! Some sandi ng can be done shoe shi ne st yl e ( f i g.
222) , but won' t have t he cut t i ng power t he ot her way does.
3. Face mi l l and r eamt he t op of t he head t ube wi t h Campagnol o
t ool #733 or equi val ent ( f i g. 78) .
7
4. Face mi l l and r eamt he bot t omof t he head t ube wi t h Campagnol o
t ool #733 or equi val ent ( f i g. 79) .
I V. THE FORK - Al l mat er i al s needed f or t he f or k have al r eady
been l i st ed. Bui l di ng t he f or k i s t he same as i t i s f or l ugged
const r uct i on. Go t o page 3- 26 and execut e al l of t he st eps f or
bui l di ng a f or k. ( #1 t hr ough #42) Ret ur n her e when f i ni shed wi t h
t he f or k.
V. THE REAR TRI ANGLE
1. I f t he f r ame has a 1- 1/ 4"
di amet er down t ube, put 1/ 16"
t hi ck washer s i n t he seat cl amp
of t he r ear end j i g as shown
i n f i g. 223 t o t he r i ght .
2. Go t o page 3- 35 and execut e
st eps 1 t hr ough 10. Af t er
compl et i ng t hose st eps, r et ur n
her e.
3. Make a choi ce.
A. Of t en, t andems and mount ai n bi kes have ext r a beef y
chai nst ays. I f t hi s i s t r ue of t he f r ame bei ng bui l t ,
t he r ear dr opout s can not be si l ver br azed i nt o pl ace
because t he gap wi l l be t oo bi g t o f i l l . So, cl ean and
pr ep t he ends of t he chai nst ays and t he dr opout s f or
br ass br azi ng ( Same pr ocedur e as used t o pr ep t he
f i l l et j oi nt s) . Appl y f l ux and br ass br aze t he dr opout s
i nt o t he ends of t he chai nst ays. Now, go t o page 3- 37
and execut e st eps 14 t hr ough 16. Af t er compl et i ng t hose
st eps, r et ur n her e.
B. I f t he chai nst ays ar e not t oo hef t y, t hey can be si l ver
br azed i n pl ace. Go t o page 3- 37 and execut e st eps 11
t hr ough 16. Af t er compl et i ng t hose st eps, r et ur n her e.
4. Mi t er t he chai nst ays so t hey wi l l span t he di st ance f r omt he
dumm axl e i n t he r ear axl e post of t he r ear end j i g t o t he
back si de of t he bot t ombr acket shel l ( f i g. 224) . Thi s i s not
a ver y di f f i cul t mi t er t o do. I t ' s j ust t edi ous. I t i s
i mpor t ant t o have bot h chai nst ays exact l y t he same l engt h i f
usi ng ver t i cal dr opout s.
5. Remove t he chai nst ays f r omt he j i g and dr i l l t wo 5/ 16" ai r
expansi on hol es i nt o t he bot t ombr acket shel l so t he
chai nst ays can vent i nt o t he bot t ombr acket ( f i g. 225) .
6. Sand t he ends of t he chai nst ays cl ean f or f i l l et br azi ng.
7. Sand t he bot t ombr acket shel l cl ean f or f i l l et br azi ng.
8- 31
LRei nst al l t he chai nst ays i nt o t he j i g, appl y br ass br azi ng
f l ux, and f or get about t hemf or a whi l e.
9. Go t o page 3- 38 and execut e st eps 26 t hr ough 47. Af t er
compl et i ng t hose st eps, r et ur n her e.
10. Tack t he chai nst ays t o t he bot t ombr acket shel l wi t h t he same
br azi ng al l oy t hat i s bei ng used t o bui l d f i l l et s ( f i g. 226) .
. 1. Si l ver br aze t he
; eat st ays ont o t he
dr opout s. ( See f i g.
37. )
12. Si l ver br aze t he
sl ugs ont o t he si des
of t he seat t ube wher e
i t meet s t he t op t ube.
( Thi s may r equi r e some
f i l l et bui l di ng wi t h
si l ver . ) ( See f i g.
138. )
. 3. Remove t he f r ame
f f r omt he r ear end j i g.
. 4. Fi ni sh bui l di ng
: he f i l l et s ar ound t he
chai nst ays wher e t hey
) ut t i nt o t he bot t om
?r acket shel l .
5. Cl ean up t he j oi nt s ar ound t he bot t ombr acket ar ea wi t h a di (
gr i nder , Dynabr ade and emer y cl ot h as descr i bed ear l i er .
6. Cosmet i cal l y cl ean up t he j oi nt wher e t he dr opout s f i t i nt o
t he seat st ays.
7. Br aze an al i en t ype seat post bi nder f i t t i ng ont o t he back }
upper par t of t he seat t ube.
18. Go t o page 3- 42 and execut e st eps 54 t hr ough 56. Af t er ]
compl et i ng t hose st eps, r et ur n her e.
VI. BRIDGES ANDBRAZE- ONS - The r est of t he f r ame can be f i ni shed
t he same way a l ugged f r ame i s f i ni shed. Go t o page 3- 42 and
f i ni sh t he f r ame as per t he i nst r uct i ons i n t he br i dges and
br aze- ons sect i on.
bearings are not so noticeable as in a machine depending solely
upon the muscles of the human body for motion. In a bicycle the
least additional friction is as quickly noticed by the experienced rider
as a stiff leg would be by a pedestrian. Experience has shown that
steel balls are the best medium to be placed between the metal sur-
faces of a bearing, and that by allowing them to roll in a circle be-
t ween hardened surfaces the wear and friction is reduced to a minimum.
It can easily be seen that the balls and bearing have to be very accurate
in size and surface, for they must be adjusted Until there is no side play,
and yet run freely. The balls used in the bearings of the Eagle are of
tool steel, drop-forged, rolled and ground. The size in the large and
small wheels is 3 12 thousandths of an inch diameter, and in the
pedals 187 thousandths of an inch diameter. Before being used each
ball is separately tested in a mi-
cr *.:- gauge, and if it vary half
a thousandth part
of an inch in diam-
eter, or from a per-
fect round, it is dis-
carded. The sec-
tional illustrations
w ill show the balls,
' cones and method
- of adjusting as used
L 't:7-7:', 1 in the Eagle. As
the balls and hear-
ing cones arc tempered PS hard
SECTION OF BALL CASE.
as glass, and are adjusted until SECTION
there is not a thousandth of an inch in play, it is very evident that if
one ball were a of an inch larger than the rest in a bearing,
it would prevent the bearing from being properly adjusted, leaving
all the other balls loose, and probably result in the breaking of the
large ball, or the injury of the cones. These bearings are all made
by us with the greatest care ; the cones, after being hardened, are
ground with an emery wheel to
insure their being perfectly true,
and every bearing is carefully
tested before the machine is al-
lowed to leave the factory.
The Eagle Pedal, while it is
in general form and appearance
similarto the usual popular form
of ball-bearing pedal, has advan-
tages in shape and method of
supporting the grip rubbers SECTION OF BEARING OF SM ALL WHEEL
PRECI SI ON MEASURI NG
I nspect i on i s of ut most i mpor t ance i n al l aspect s of our hi gh
t ech wor l d. Fr omspace shot s whi ch send men t o t he moon, t o
mi cr opr ocessor s, t o nucl ear r eact or s, t o pl ast i c chess pi eces, we
al ways need t o know what qual i t y we ar e t ur ni ng out . Pr oper
i nspect i on t echni ques wi l l t el l us t hi s. Two hundr ed year s ago
cr af t smen made f l i nt l ock r i f l es by hand. Par t s wer e not
i nt er changeabl e, and when somet hi ng had t o be r epl aced, a new
pi ece had t o be made by hand. Ther e was no guar ant ee f r omone
r i f l e t o t he next of what si ze par t s woul d be or even t he qual i t y
of each par t . Then, i n 1798, El i Whi t ney was gi ven a gover nment
cont r act t o pr oduce 10, 000 musket s. Whi t ney f el t t hat par t s
shoul d be i nt er changeabl e
f r omone gun t o t he next ,
and consequent l y i nt r oduced 10 THE EAGLE BICYCLE MFG. COMPANY.
"t he uni f or mi t y syst em". By
t he t i me of t he bi cycl e boom
i n t he 1800' s i nt er -
changeabl e par t s wer e a par t
of ever yday l i f e. And at
t hat t i me, i nspect i on of
manuf act ur ed par t s had
become qui t e sophi st i cat ed.
On t he r i ght i s an exer pt
f r oman 1891 edi t i on of t he
Eagl e Bi cycl es cat al ogue
t hat bear s t hi s out : Not
ver y t i ght t ol er ances back
t hen, wer e t her e? Of
cour se, our Numer ex
machi nes, Cor dax machi nes,
and Laser beams of t oday
have l ef t our gr andf at her s
i n t he dust . The i mpor t ant
quest i on i s whet her bi cycl e
f r amebui l der s have l ef t
t hei r gr andf at her s i n t he
dust as wel l . Ther e ar e
st i l l bi cycl e f r amebui l der s
t oday who ar e bui l di ng bi kes
l i ke t he f l i nt l ock maker s of
bygone days. They have no
i dea what head t ube angl e a
bi ke has when i t r ol l s out
t he door . They have no way
of pr edi ct i ng what head t ube
angl e t he next f r ame wi l l
have. They have no way of
pr oduci ng a f or k wi t h a
9- 1
speci f i ed amount of r ake. They don' t even know i f a br ake br i dge
wi l l be t he cor r ect hei ght f or a shor t r each br ake and keep t he
dr opout s 126mmapar t at t he same t i me. Some bui l der s si mpl y
di smi ss t he i mpor t ance of whet her t hei r bi kes meet specs or not .
Peopl e who bui l d f r ames l i ke t hi s ar e i n t he same l eague wi t h t he
f l i nt l ock maker s of yest er year .
One par t of i nspect i on i s pr eci si on measur i ng whi ch can and
shoul d be done by t he f r amebui l der . I n t he ear l i er exer pt , i t was
pl ai n t o see t hat t hei r t ol er ances wer e not ver y cl ose back t hen.
Af t er al l , bear i ngs t oday come i n t ol er ances of pl us or mi nus
. 000003"! ( That ' s r i ght - t hr ee mi l l i ont hs. ) The next quest i on
i s, "Why woul d anyone want t o measur e a f r ame down t o mi l l i ont hs
of an i nch?" No one woul d, and anyone who t r i es i s cr azy. The
i dea i s t o at t ai n a happy medi umsomewher e bet ween t he f l i nt l ock
maker and t he aer ospace engi neer . By doi ng i nspect i on of bi cycl e
f r ames i n t he f or mof pr eci si on measur i ng, t he bui l der can mor e
conf i dent l y ensur e t he qual i t y cont r ol of t he f r ame. By choosi ng a
r ange of t ol er ances t hat ar e not t oo har d t o achi eve but t i ght
enough t o ensur e uni f or mi t y f r omone f r ame t o t he next , t he
bui l der knows exact l y wher e he st ands and can i mpr ove accor di ngl y.
WHAT I S PRECI SI ON MEASURI NG?
I t ' s easy t o measur e t he wi dt h of a pi ece of wr i t i ng paper
wi t h a r ul er . I t ' s 8- 1/ 2". Any second- gr ader can do t hat . How
about measur i ng i t s t hi ckness? That ' s not so easy. The r ul er
won' t wor k any mor e. We need somet hi ng mor e accur at e, somet hi ng
t hat i s cal i br at ed i n smal l er uni t s. Thi s i s t he f i r st aspect of
pr eci si on measur i ng- - MI NUTE CALI BRATI ON. I n or der f or i t
t o be a pr eci si on measur ement , i t must be t i ny. Measur ement s
i n cal i br at i ons smal l er t han 1/ 64" can be consi der ed pr eci si on i n
nat ur e.
Measur e t he head of a pi n wi t h a r ul er and wr i t e down t he
answer . Then hand t he pi n and r ul er t o anot her per son and have
hi mdo t he same. Pass i t on t o t he next per son and so on.
Compar e answer s. Chances ar e, t hey ar e not t he same. Wi t h a
mi cr omet er , t he answer s woul d be al l t he same or so cl ose t hat
t her e woul d be l i t t l e ar gument . Thi s br i ngs us t o t he second
concept of pr eci si on measur i ng- - REPEATABI LI TY. No mat t er how many
t i mes t he obj ect i s measur ed or who measur es i t , t he answer i s t he
same.
Ask a j ockey how t al l a hor se i s. He may t el l you i t i s 14
hands hi gh. Ask an Engl i shman how heavy he i s. He may t el l you
he wei ghs 12 st ones. Ask a yacht sman how f ast he i s t r avel i ng.
He may t el l you 12 knot s. Ask an acupunct ur i st how f ar i t i s
f r omyour nose t o your ear l obe. He may say i s i s 4 puces.
I nches, hogsheads, l eagues, deci st er s, cubi t s, f eet , bar r el s,
dr ums, acr es, hect ar es, bar ns, sheds, and AU' s ar e al l
measur ement s of one sor t or anot her . Each i s based on a di f f er ent
9- 2
uni t and many have no r el at i on t o one anot her . Pr eci si on
measur i ng, i n t hi s count r y, bases ever yt hi ng on t he i nch and
deci mal di vi si ons t her eof . Mor e advanced count r i es base t hei r
pr eci si on measur ement on mi l l i met er s and di vi si ons t her eof . Thi s
i s t he l ast aspect of pr eci si on measur i ng- - STANDARDI ZATI ON. The
I . S. O. di ct at es t o us whi ch uni t s we wi l l use i n pr eci si on
measur ement .
DI VI DI NG UP THE I NCH AND CENTI METER
Ther e ar e t hr ee di f f er ent popul ar met hods of r eadi ng t he
measur ement s t aken i n an i nspect i on r oom:
A. THE LED READOUT- Wi t h t he comi ng of mi cr ochi ps and
comput er s, we now have t hose r ed squar e shaped
number s on ever yt hi ng f r omchi l dr en' s t oys t o space
shut t l e cont r ol panel s. A var i et y of pr eci si on t ool s
comes wi t h LED r eadout s, cer t ai n model s of mi cr omet er s,
cal i per s, and hei ght gages come wi t h t hi s l uxur y. A
t ool wi t h an LED r eadout can be r ead wi t h no pr act i ce
and no knowl edge of how t he t ool wor ks. I f you can
af f or d t ool s such as t hi s, go ahead and buy t hem.
B. THE DI AL I NDI CATOR- Many pr eci si on t ool s come equi pped
wi t h a r ound di al wi t h a needl e t hat gi ves r eadi ngs i n
i ncr ement s of t housandt hs or t en- t housandt hs. ( Fr omnow
on t en- t housandt hs wi l l be si mpl y r ef er r ed t o as
t ent hs. ) These t oo ar e r el at i vel y easy t o r ead and can
be f i gur ed out i n a f ai r l y shor t amount of t i me.
C. THE VERNI ER SCALE- Most t ool s wi l l have a scal e al ong
t he si de of t he mai n scal e of t he t ool . Thi s auxi l i ar y
or ver ni er scal e t akes t i me t o l ear n and r equi r es
pr act i ce t o use i t wel l . Si nce most of t he t ool s you
buy wi l l be equi pped wi t h a ver ni er , t hat i s t he scal e
t hat wi l l be di scussed i n t hi s book.
Per haps t he best t ool t o st ar t wi t h i s t he ver ni er cal i per .
Fi r st of al l , i t i s r el at i vel y i nexpensi ve. Secondl y, i t i s a
t ool t hat no f r amebui l der or bi ke mechani c shoul d be wi t hout .
Thi r dl y, i t has a ver ni er and i s r ead much t he same way as any
ot her of t he pr eci si on t ool s havi ng a ver ni er scal e.
Look at t he mai n scal e f i r st . I t consi st s of a shaf t t hat i s
usual l y 6" l ong. One edge of t he mai n scal e wi l l have i nches
br oken down i nt o t en equal par t s; each t ent h of an i nch shoul d be
consi der ed 100/ 1000" ( wr i t t en . 100" - see f i g. 228) . Now, l ook a
l i t t l e cl oser . Each di vi si on of . 100" i s br oken up agai n i nt o 4
equal par t s. These smal l er di vi si ons ar e 25/ 1000" ( wr i t t en . 025"
- see f i g. 229) . When we t ake a measur ement , we have t o add t hese
val ues up i n our heads.
9- 3
Ther e i s a st at i onar y j aw and a sl i di ng j aw on t he cal i per .
Not i ce t hat al ong one edge of t he sl i di ng j aw i s a ser i es of
number s f r om0 t o 25. Thi s set of number s i s t he ver ni er scal e.
A ver y cl ose i nspect i on of t he ver ni er scal e shows t hat onl y one
mar k on t he ver ni er l i nes up wi t h one mar k on t he mai n scal e. I f
t he 7 mar k on t he ver ni er l i nes up wi t h a mar k on t he mai n scal e
no ot her mar ks l i ne up. Ther ef or e t he 7 shoul d be made not e of .
Fi g. 230 hel ow shows a cal i per on whi ch t he 7 mar k l i nes up.
Now l et ' s t r y a measur ement . Sl i de t he j aws t oget her on t he
down t ube of a bi cycl e f r ame. We must wat ch t he l ocat i on of t he
zer o on t he ver ni er scal e. Let ' s add up t he di vi si ons we have
9- 4
gone past wi t h t hat zer o. We have passed t he l ar ge number 1 on
t he mai n scal e but haven' t come t o t he l ar ge number 2 yet . I n
ot her wor ds, we have gone one i nch but not yet t wo i nches. Wr i t e
down 1. 000" on a pi ece of paper . Now l et ' s l ook at t he smal l er
set of number s bet ween t he l ar ge 1 and t he l ar ge 2. Not e t hat we
have passed t he smal l number 1 wi t h our ver ni er zer o but have not
yet come t o t he smal l number 2. I n ot her wor ds, we have gone
. 100" but not yet . 200". Wr i t e 0. 100" bel ow t he ot her number on
t hat pi ece of paper . Now l et ' s l ook at t he f our t i ny di vi si ons
af t er t he smal l number 1 on t he mai n scal e. I f you squi nt , you
can see we have j ust bar el y gone past t he f i r st mar k af t er t he
smal l number 1 ( For t hose of you who ar e mor e exper i enced, don' t
f or get t he coat of pai nt adds . 002" t o t he r adi us of t he t ube. ) .
Thi s means we have gone . 025" but have not yet come t o . 050".
Wr i t e down 0. 025" under t he t wo ot her number s on t hat pi ece of
paper . Let ' s l ook at t he ver ni er now. Whi ch mar k on t he ver ni er
scal e l i nes up wi t h a mar k on t he mai n scal e? Hopef ul l y, i t wi l l
be t he 4, whi ch means . 004". Wr i t e 0. 004" on t he pi ece of paper .
The next st ep i s t o add t he f our number s up t o get t he answer f or
t he measur ement . The ver ni er i n f i g. 231 bel ow shows t he r eadi ng
we j ust t ook.
1. 000"
0. 100"
0. 025"
+ 0. 004"
1. 129"
The met r i c ver si on i s done i n
exact l y t he same way. The phot o 2. 00cm 2. 00cm
above shows 2 whol e cent i met er s 9. 00mmOR . 9cm
pl us 9whol e mi l l i met er s pl us . 7 . 7mm + . 07cm
mi l l i met er s on t he ver ni er scal e. 7 2. 97cm
Thi nk of 9mi l l i met er s as . 9
cent i met er s and . 7 mi l l i met er s as 20. omm
. 07 cent i met er s. Now add t he 9. Omm
t hr ee val ues up as done on t he OR + .7mm
r i ght . A good cal i per wi l l have 29. 7mm
bot h Met r i c and Engl i sh cal i br at -
i ons on i t .
9- 5
That i s measur i ng wi t h a ver ni er cal i per . By f ol l owi ng t hose
st eps of r ecor di ng and addi ng t he successi ve i ncr ement s on t he
mai n scal e and ver ni er scal e, any measur ement f r om0" t o 6" can be
t aken. The ver ni er hei ght gage ( f i g. 232) has a si mi l ar scal e and
can be adapt ed t o al most i nst ant l y af t er l ear ni ng t he ver ni er
cal i per . The bevel pr ot r act or ( f i g. 233) i s al so qui t e easy t o use
af t er mast er i ng t he ver ni er cal i per . The onl y di f f er ences wi t h
t he ver ni er on t he bevel pr ot r act or ar e t hat i t i s on a cur ved
sur f ace and i t measur es degr ees and mi nut es i nst ead of i nches or
cent i met er s.
Anot her t ool t hat al l f r amebui l der s shoul d be f ami l i ar wi t h i s
t he mi cr omet er . The mi cr omet er i s al so avai l abl e wi t h LED
r eadout s or wi t h a ver ni er scal e. However , most bui l der s wi l l have
no need t o go t o such smal l i ncr ement s wi t h a mi cr omet er . ( A
mi cr omet er wi t h a ver ni er scal e measur es down t o "t ent hs". )
Ther ef or e, a st andar d "mi ke" wi t h no auxi l i ar y scal e i s
suf f i ci ent .
Mi kes come i n di f f er ent si zes t oo. Each mi ke onl y measur es a
span of an i nch ( 25mmf or met r i c model s) . I n ot her wor ds, t he
smal l est si ze mi ke wi l l measur e anyt hi ng f r om0" t o 1". t he next
si ze wi l l measur e f r om1" t o 2", and so on. A 1" mi ke i s a good
i t emt o own. A 2" mi ke i s opt i onal - most bui l der s coul d get al ong
wi t hout i t . A 3" mi ke i s quest i onabl e - about t he onl y t hi ng t hat
can be measur ed wi t h i t i s bot t ombr acket wi dt h. A 4" mi ke i s
get t i ng t oo ext r avagant f or t he aver age f r amebui l der . I t has no
use i n f r amebui l di ng. A 5" mi ke coul d be used t o measur e hub
wi dt hs but i s not r eal l y necessar y. Wi t h bi cycl es, Met r i c mi kes
wor k wel l si nce specs ar e usual l y i n met r i c.
9- 6
Measur i ng wi t h a mi ke i s si mi l ar t o measur i ng wi t h a ver ni er
cal i per but due t o some basi c di f f er ences, i t wi l l be expl ai ned
her e br i ef l y. The mi cr omet er i s made up of ei ght mai n par t s as
shown i n f i g. 234 bel ow:
When measur i ng wi t h t he mi ke, put t he pi ece t o be measur ed
bet ween t he anvi l and t he spi ndl e. Ti ght en t he t hi mbl e by t ur ni ng
t he r at chet st op wi t h t he t humb and f or ef i nger . When t he r at chet
cl i cks 2 or 3 t i mes, t he mi ke i s t i ght enough f or a r eadi ng. The
mi ke i s r ead f i r st i n i nches, t hen i n set s of hundr edt hs, t hen i n
set s of t went y- f i ve t housandt hs, t hen i n i ndi vi dual t housandt hs.
Thi s i s si mi l ar t o t he ver ni er cal i per but t he whol e set - up i s
r ead si deways whi l e i t i s wr apped ar ound a cyl i nder ( t he sl eeve) .
To get t he number of whol e i nches, t ake t he f i r st of t he t wo
number s t hat desi gnat e t he si ze of t he mi ke and wr i t e t hat down on
a pi ece of paper . For exampl e; i f i t i s a 0" t o 1" mi ke, wr i t e
down 0. 000". I f i t i s a 1" t o 2" mi ke, wr i t e down 1. 000". I f i t
i s a 2" t o 3" mi ke, wr i t e down 2. 000" - and so on.
To get hundr edt hs, not e how t he t hi mbl e wi l l cover up t he
number s on t he sl eeve as i t i s scr ewed down t owar d t he pi ece t o be
measur ed. Fi nd t he l ar gest number on t he sl eeve t hat i s st i l l
vi si bl e and wr i t e t hat down on t he paper as f ol l ows; I f 3 i s t he
l ar gest number showi ng, wr i t e down . 300". I f 7 i s t he l ar gest
number showi ng, wr i t e down . 700", et c.
Gr oups of t went y- f i ve t housandt hs can be r ead i n t he same way
as wi t h t he cal i per . Wr i t e down how many gr oups of t went y- f i ve
t housandt hs appear af t er t he hi ghest vi si bl e number on t he sl eeve
but bef or e t he t hi mbl e. I f onl y one gr oup appear s, wr i t e down
. 025". I f t wo gr oups appear , wr i t e down . 050". I f t hr ee gr oups
appear , wr i t e down . 075".
9- 7
To get i ndi vi dual t housandt hs, l ook at t he set of number s t hat
enci r cl e t he t hi mbl e. These number s r ange f r om0 t o 25 and onl y
one of t hemwi l l l i ne up wi t h t he mai n l i ne on t he sl eeve. I f t he
7 l i nes up, wr i t e down . 007". I f t he 12 l i nes up, wr i t e down
. 012", et c.
Her e i s a pr act i cal exampl e.
The mi ke pi ct ur ed i n f i g. 235
bel ow, i s a 0" t o 1" mi ke, so wr i t e
down 0. 000". Not e t hat t he hi ghest 0. 000"
number st i l l vi si bl e on t he sl eeve . 400"
i s 4. Wr i t e down . 400". Two . 050"
gr oups of t went y- f i ve t housandt hs + . 013"
ar e showi ng, so wr i t e down . 050". 0. 463"
The number 13 l i nes up wi t h t he
l i ne on t he sl eeve, so wr i t e down
. 013". Now, add up t he col umn of
f i gur es. Your answer shoul d be
0. 463". Wi t h pr act i ce, al l of t hi s
can be done ment al l y wi t hout
wr i t i ng f i gur es down.
Af t er f ami l i ar i t y i s est abl i shed wi t h ver ni er cal i per s and
mi cr omet er s, many ot her pr eci si on t ool s wi l l be easy t o r ead and
i nt er pr et . The ver ni er scal e i s an i nt egr al par t of many
pr eci si on t ool s and t he mi cr omet er head can be f ound mount ed t o
pr eci si on t ool s as wel l as f i xt ur es. Ar med wi t h t hi s knowl edge of
r eadi ng t he scal es of pr eci si on t ool s, you' r e r eady t o go on t o
f i nd out mor e about t hei r appl i cat i ons i n bi cycl e f r amebui l di ng.
WORKI NG ON THE SURFACE PLATE
A sur f ace pl at e can be made of gr ani t e, mar bl e, or a pi ece of
bl anchar d gr ound st eel . St one sur f ace pl at es ar e commer ci al l y
made and ar e def i ni t el y f ar super i or t o met al pl at es whi ch ar e
usual l y or der ed t o specs f r oma bl anchar d gr i ndi ng company. The
mai n i t ems t o consi der i n choosi ng a sur f ace t abl e ar e; STABI LI TY,
TOLERANCES, SI ZE, MATERI AL, and FI NI SH.
STABI LI TY
How wel l does t he t abl e hol d i t s shape and f l at ness
over t he year s? St one i s by f ar t he most st abl e. Cast
i r on and col d r ol l ed st eel come i n a cl ose second.
St one i s af f ect ed ver y l i t t l e by heat , col d, humi di t y,
or pr essur e. Var i at i ons i n f l at ness can be obser ved
wi t h met al t ops. I f t he pl at e wi l l be kept i nsi de a
heat ed shop and suppor t ed under neat h subst ant i al l y,
t her e shoul d be no pr obl ems wi t h t he st abi l i t y of a
met al t abl e.
TOLERANCES
How accur at el y i s t he t abl e gr ound? St one pl at es
ar e gr ound t o pl us or mi nus . 0002" or l ess. A bl anchar d
gr ound st eel pl at e wi l l pr obabl y be gr ound t o t ol er ances
of pl us or mi nus . 005". For most appl i cat i ons i n
f r amebui l di ng, a bl anchar d gr ound pl at e wi l l be
adequat e. Ti ght er t ol er ances al ways cost mor e. I f t he
budget can handl e i t , by al l means get t he mor e pr eci se
st one pl at e.
SI ZE
Sur f ace pl at es come i n a var i et y of si zes. Some may
be as smal l as 6" squar e and ot her s may be as bi g as 10
or 20 f eet acr oss. I n choosi ng t he si ze of a sur f ace
t abl e, onl y one consi der at i on must be wei ghed. How l ong
i s t he l ongest span t hat wi l l ever be measur ed on t hi s
pl at e? I deal y, si nce f r ames sel domget l onger t han 40"
f r omt he r ear dr opout s t o t he head t ube, a 40" l ong
pl at e woul d be ni ce. I n t he ot her di r ect i on, bi cycl es
sel domget t al l er t han a 27" seat t ube so, a 27" wi de
pl at e woul d be ni ce. A st eel , bl anchar d gr ound pl at e of
t hese di mensi ons shoul d be at l east 1" t hi ck. St one
pl at es have t hi ckness pr edet er mi ned by t he manuf act ur er .
That ' s a pr et t y bi g pl at e and a l ot of st eel or st one t o
own. To cut cor ner s, a f r amebui l der coul d cut t he
l engt h by a t hi r d and f l i p- f l op t he f r ame i f necessar y.
That shoul d get i t down t o a wor kabl e si ze and an
af f or dabl e pr i ce.
9- 9
MATERI AL
St one pl at es ar e commonl y avai l abl e i n pi nk or bl ack
gr ani t e. Ei t her i s mor e t han adequat e f or f r amebui l di ng
appl i cat i ons. Met al pl at es coul d be made of al most
anyt hi ng, but shoul d onl y be made of cast i r on or
col d- r ol l ed st eel . Of al l t he met al s avai l abl e, t hese
t wo wi l l pr ove t o be t he most st abl e. Avoi d al umi numor
st ai nl ess st eel sur f ace pl at es. They wi l l bot h do a
hul a dance dur i ng a 20 degr ee t emper at ur e change!
FI NI SH
Of cour se a f i ne f i ni sh i s of t he ut most i mpor t ance
i n sel ect i ng a sur f ace pl at e. Bl anchar d gr i ndi ng wi l l
l eave a pat t er n of r adi at i ng ar cs i n t he sur f ace of t he
st eel . These gr ooves ar e ext r emel y f i ne but ,
never t hel ess, can be f el t whi l e l i ght l y r ubbi ng a hand
over t he sur f ace. Tool bases wi l l si t ni cel y on t op of
t hese mar ks wi t h no pr obl em. The onl y way t o get t he
st eel sur f ace smoot her i s t o have i t pr eci si on gr ound.
( Thi s woul d add so much t o t he cost of t he pl at e t hat i t
woul d be j ust as cheap t o buy a st one pl at e. ) St one
pl at es may have a gl ossy or sat i n f i ni sh. The t heor y i s
t hat t he sat i n f i ni sh does not al l ow a cushi on of ai r t o
devel op under t he t ool base. Any of t hese f i ni shes ar e
mor e t han adequat e f or f r amebui l di ng appl i cat i ons.
ALTERNATE SOURCES FOR SURFACE PLATES
I t i s not al ways necessar y t o l ay out a l ar ge amount of cash
f or a sur f ace pl at e. Sur f ace pl at es ar e i n abundance ar ound us
ever y day. The t op of a l ar ge t abl e saw makes a beaut i f ul sur f ace
pl at e af t er t he bl ade i s dr opped and t he f ence r emoved. Sur f ace
pl aner beds, dr i l l pr ess t abl es, j oi nt er t abl es, mar bl e t abl e
t ops and even gr avest ones can be used as sur f ace pl at es. One
good sour ce of f i ne sur f ace pl at es i s ol d pr i nt er ' s t ypeset t i ng
t abl es. They ar e made of mar bl e and ar e gr ound t o f i ne
t ol er ances. They ar e al so r eadi l y avai l abl e because of t he
massi ve t echnol ogi cal changes i n t he pr i nt i ng i ndust r y. ( I was
l ucky enough t o f i nd 2 of t hemf or l ess t han $100. 00 api ece! )
Hunt ar ound.
ONE FI NAL WORDABOUTSTEEL SURFACE PLATES
Ther e ar e t wo dr awbacks t o usi ng st eel sur f ace pl at es. Fi r st
of al l , t hey r ust . Keep t heml i ght l y oi l ed and away f r omhumi di t y
or dr i ppi ng wat er sour ces. Second, t hey dent . I f somet hi ng har d
and heavy i s dr opped on a st eel pl at e, i t wi l l l eave a dent and an
adj acent hi gh spot . Be car ef ul .
9- 10
BI LATERAL SYMMETRY
Li ke human bei ngs, bi cycl e f r ames have bi l at er al symmet r y. I n
ot her wor ds, i f we sl i ce a bi cycl e f r ame down t he cent er t o spl i t
i t evenl y i nt o r i ght and l ef t hal ves, each hal f wi l l be a mi r r or
i mage of t he ot her i n ever y sense. I f t he f r ame i s damaged or
bui l t mi sal i gned, t he hal ves wi l l be sl i ght l y di f f er ent f r omeach
ot her . When we mount a f r ame on a sur f ace pl at e, we wi l l be
l ooki ng f or t hese var i at i ons i n bi l at er al symmet r y. I f t he seat
t ube has def l ect i on as i t l eaves t he bot t ombr acket , i f t he
dr opout s ar e bot h t o one si de, or i f t he head t ube has t wi st , t hi s
bi l at er al symmet r y i s al t er ed. I n whi ch case, t he pr obl emmust be
r emedi ed, t ol er at ed, or t he f r ame di sposed of .
MOUNTI NG THE FRAME TO THE SURFACE PLATE
Bef or e doi ng any i nspect i on of t he f r ame set what soever , t he
bot t ombr acket f aces must be f aced wi t h a Campagnol o t ool #725 or
an equi val ent t hat uses i nser t ed gui des. Af t er t hey ar e f aced,
t he f aces of t he bot t ombr acket shel l pr ovi de one of t he most
accur at e sur f aces t o l ocat e agai nst .
The f r ame must be mount ed above t he sur f ace pl at e so t hat t he
bot t ombr acket f aces ar e par al l el t o t he sur f ace of t he pl at e. I f
t her e ar e no mount i ng hol es i n t he sur f ace pl at e, a heavy
count er bal ance can be machi ned t o secur e t he f r ame i n t he pr oper
posi t i on ( See f i g. 236) . I f t hr eaded hol es ar e pr ovi ded i n t he
sur f ace pl at e a mor e si mpl e mount i ng devi ce can be machi ned ( See
i l l ust r at i on #127 bel ow. )
9- 11
When t he f r ame i s mount ed hor i zont al l y on t he pl at e, t he f r ont
and r ear t r i angl es may be checked t o see i f any of t he t ubes
devi at e f r omt he cent r al pl ane of t he f r ame. I f t her e i s any
devi at i on, st r ai ght eni ng shoul d not be done whi l e t he f r ame i s
mount ed i n t he i nspect i on f i xt ur es. For ci ng and t or qui ng on
i nspect i on f i xt ur es wi l l onl y ser ve t o t ake t hemout of t ol er ance.
I f t hat happens, t hey become usel ess. I deal l y, t he cr ooked f r ame
shoul d be r emoved f r omt he i nspect i on f i xt ur es, pl aced i n a Par k
FRS- 1 st and and st r ai ght ened t her e. ( Use of t he FRS- 1 st and wi l l
be cover ed i n t he f r ame r epai r sect i on avai l abl e i n August of
1986. )
CHECKI NG FOR SEAT TUBE DEFLECTI ON
Per haps t he f i r st i t emt o check i s whet her t he seat t ube i s
def l ect ed t o t he l ef t or r i ght as i t l eaves t he bot t ombr acket
shel l . ( J ust as a human bei ng, a bi cycl e f r ame has a l ef t and a
r i ght si de. Even when a per son l i es i n bed on t hei r si de, t hei r
l ef t hand i s st i l l l ef t and t he r i ght hand i s st i l l r i ght . The
same goes f or a f r ame. ) To det er mi ne whet her a seat t ube has
def l ect i on, pl ace t he scr i be of t he ver ni er hei ght gage on t he
seat t ube cl ose t o t he bot t ombr acket shel l and t ake a r eadi ng
( f i g. 237) . Now sl i de t he ver ni er hei ght gage up cl ose t o t he seat
l ug and t ake anot her r eadi ng ( f i g. 238) . The di f f er ence of t he t wo
r eadi ngs i s t he amount of def l ect i on. ( Remember when we di d a
si mi l ar check wi t h t he bot t ombr acket mi ke? The amount of
def l ect i on was 1/ 2 of t he di f f er ence bet ween t he t wo r eadi ngs.
Not so on t he sur f ace pl at e. The r eadi ngs ar e onl y t aken on one
si de of t he f r ame, so t he di f f er ence bet ween t he t wo r eadi ngs i s
t he act ual def l ect i on. )
9- 12
How much def l ect i on i s accept abl e? I n t he case of mass
pr oduced f r ames, def l ect i on of as much as . 250" over a span of 18"
i s f ai r l y common! That i s not t o say i t i s accept abl e. However ,
consi der t he pr i ce r ange of t he bi ke. Di d t he cust omer even pay
f or t i ght t ol er ances? On mor e expensi ve f r ameset s, def l ect i on of
. 125" may be qui t e common. On a hi gh qual i t y l i mi t ed pr oduct i on
f r ameset , def l ect i on of mor e t han . 050" shoul d be consi der ed
unaccept abl e. I n t he case of a cust omf r ame, an exper i enced
bui l der shoul d easi l y be abl e t o keep t hat f i gur e under . 050" and
wi t h pr act i ce appr oach r eadi ngs as smal l as . 025" def l ect i on.
CHECKI NG FOR DOWN TUBE DEFLECTI ON
Checki ng f or down t ube def l ect i on i s done t he same way as
checki ng f or seat t ube def l ect i on. Take t he f i r st r eadi ng cl ose
t o t he bot t ombr acket shel l ( f i g. 239) . Take t he second r eadi ng
j ust bel ow t he poi nt wher e t he down t ube meet s t he head t ube ( f i g.
240) The same t ol er ances appl y.
"Aha, " some of t he mor e exper i enced r eader s may be sayi ng,
"These t ubes ar e not al ways per f ect l y r ound! " Thi s i s t r ue. I f a
mor e accur at e r eadi ng i s desi r ed, mount a di al i ndi cat or t o t he
ver ni er hei ght gage and t ake a const ant r eadi ng al ong t he ent i r e
l engt h of t he t ube. Thi s i s what i s commonl y cal l ed spl i t t i ng
hai r s. Aver age r unout on even t he hi ghest qual i t y t ubi ng can be
as much as . 005" out of r ound on t he r adi us. Thi s shoul d be t aken
i nt o consi der at i on i n i nspect i on t echni ques. I f r unout i s . 005",
a per son i s cr azy t o t r y t o hol d t ol er ances of l ess t han . 005". A
f r ame hol di ng t ol er ances of l ess t han . 010" mi ght occur on an
aver age of 1 out of 100 f r ames. Tol er ances of . 015" woul d be
qui t e di f f i cul t t o achi eve. Tol er ances of . 025" over a span of
18" ar e mor e r easonabl e.
241
MEASURI NG HEAD TUBE TWI ST
Head t ube t wi st r ef er s t o t he pr obl emof havi ng a head t ube
t hat l i es i n a pl ane t hat i s askew wi t h t he pl ane of t he seat
t ube. Thi s woul d cause t he bi ke' s wheel s t o r un i n di f f er ent
t r acks, whi ch coul d r esul t i n sever e handl i ng pr obl ems. Readi ngs
can be t aken by mount i ng a di al i ndi cat or t o t he hei ght gage and
f i ndi ng t he l ow spot on t he pr ess f i t di mensi on t hat accept s t he
l ower head cup ( f i g. 241) . Set t he di al at zer o and t hen t ake t he
same measur ement on t he pr ess f i t di mensi on t hat accept s t he upper
head cup ( f i g. 242) .
Let ' s say t hat t he f i r st measur ement i s 8. 763" up f r omt he
sur f ace pl at e and t he second measur ement i s 8. 863" up f r omt he
sur f ace pl at e. Now measur e t he l engt h of t he head t ube. Let ' s say
i t ' s 6. 000" l ong. Thi s means t hat t he head t ube r i ses away f r om
t he sur f ace pl at e . 010" over a span of 6. 000". Thi s doesn' t mean
much unt i l we compar e i t wi t h a 6. 000" l engt h of t he seat t ube.
Take a hei ght measur ement anywher e al ong t he seat t ube. Now, t ake
anot her one 6. 000" away f r omt he f i r st one. Recor d how much t he
seat t ube r i ses or f al l s over a span of 6. 000". Compar e t hi s wi t h
how much t he head t ube r i ses or f al l s i n t hat amount of di st ance.
I f t hey bot h r i se t he same amount , t hat ' s OK. I f t hey bot h f al l
t he same amount , t hat ' s OK. I f t her e i s a di f f er ence bet ween t he
t wo, t her e may be a pr obl em. Tol er ances shoul d be t i ght on head
t ube t wi st . I f t he head t ube r i ses or f al l s over . 010" mor e t han
t he seat t ube, t he wheel s wi l l be r unni ng i n di f f er ent t r acks at
l east . 060" apar t wher e t hey meet t he gr ound. St r i ve f or a
di f f er ence of r i se or f al l bet ween t he head t ube and seat t ube of
no mor e t han . 010" over a span of 6. 000".
9- 14
245
246
CHECKI NG THE REAR TRI ANGLE PLANE
I n checki ng t he pl ane of t he r ear t r i angl e, t he f i r st t hi ng
t hat must be done i s t o est abl i sh t he t heor et i cal cent er of t he
bot t ombr acket shel l . The easi est way t o do t hi s i s t o t ake a
hei ght r eadi ng of t he sur f ace on t he f i xt ur e wher e t he bot t om
br acket shel l r est s ( f i g. 243) . Then get a hei ght r eadi ng of t he
sur f ace t hat comes i n cont act wi t h t he ot her bot t ombr acket f ace
( f i g. 244) . The hal f - way poi nt bet ween t hese t wo measur ement s i s
t he t heor et i cal cent er of t he bot t ombr acket shel l . A good way t o
obt ai n t hese measur ement s i s t o use t he uni ver sal gage as shown
bel ow.
Af t er t he hei ght s ar e f ound wi t h t he uni ver sal gage, t hey can
be quant i f i ed i nt o i nches or cent i met er s by one of t wo met hods as
shown i n f i gur es 245 and 246 bel ow.
9- 15
When t he t heor et i cal cent er ( TC) has been est abl i shed,
measur ement s can be t aken on t he r ear dr opout s. Fi r st , t ake a
hei ght measur ement t o t he i nsi de f ace of t he dr opout cl osest t o
t he sur f ace pl at e ( f i g. 247) . Cal l t hi s measur ement Hl . Then t ake
a hei ght measur ement on t he out si de f ace of t he dr opout f ur t hest
f r omt he sur f ace pl at e ( f i g. 248) . Cal l t hi s measur ement H2. Take
a r eadi ng of t he t hi ckness of a dr opout ( f i g. 249) . Cal l t hi s
measur ement T.
Wi t h t hese val ues, t he exact or i ent at i on of t he r ear t r i angl e
can be det er mi ned.
Dr opout Spaci ng ( f or hub wi dt h) = H2 - H1 - T
Wi t h t he Dr opout Spaci ng ( DS) and t he TC a t heor et i cal r ear
t r i angl e can be set up. The t heor et i cal r ear t r i angl e di agr amcan
be f i l l ed i n wi t h number s t hat woul d si mul at e a per f ect r ear
t r i angl e wi t h t he gi ven TC and DS. Her e ar e f or mul as t o f i l l out
t he di agr am.
Theor et i cal H1 = TC - ( . 5 X DS)
Theor et i cal H2 = TC + ( . 5 X DS) + T
9- 16
Her e i s t he di agr amt o f i l l i n wi t h t he TC, DS, Theor et i cal
H1, and Theor et i cal H2.
Now, t ake t he act ual H1 and H2 f ound on t he sur f ace pl at e and
compar e t hemwi t h t he t heor et i cal H1 and H2 f i gur es. Thi s i s wher e
t he al i gnment of t he r ear t r i angl e i s det er mi ned. I deal l y, H1
shoul d mat ch Theor et i cal H1 and H2 shoul d mat ch Theor et i cal H2.
I f t her e i s not a mat ch, col d set t i ng must be done t o cor r ect
t hi s. Tol er ances t hat mi ght be expect ed on a t op not ch cust om
f r ame woul d be pl us or mi nus . 025". I f t her e i s a bad mat ch
bet ween t he t heor et i cal measur ement s and t he act ual measur ement s,
t hi s wi l l show up as bad chai n l i ne whi ch coul d cause such
pr obl ems as excessi ve chat t er i n cer t ai n gear s, excessi ve r ubbi ng
on t he i nsi de f ace of t he out er chai nr i ng or even unwant ed
"aut omat i c" shi f t i ng i n cer t ai n gear s.
MOUNTI NG THE FRAME VERTI CALLY ON THE SURFACE PLATE
Ver t i cal mount i ng r equi r es t wo i t ems: 1- t he f or k t hat was
bui l t t o mat ch t he f r ame and 2- ei t her a r eal or dummy headset . A
set of dummy hubs ar e mount ed i n a pai r of V- bl ocks ( f i g. 250) .
The dr opout s ar e t hen set i n pl ace on t he dummy hubs ( f i gs. 251 &
252) . The V- bl ocks ar e t hen set on t op of par al l el s or some ot her
t ype of pr eci si on pedest al ( f i gs. 251, 252, & 253) . Wi t h t he f r ame
i n t hi s posi t i on ( f i g. 253) , bot t ombr acket dr op, seat t ube angl e,
and head t ube angl e can be measur ed.
9- 17
Seat t ube angl e can be measur ed by mount i ng a bevel pr ot r act or
on a ver ni er hei ght gage and r est i ng t he bl ade agai nst t he t ube
( f i g. 254) . Head t ube angl e i s t aken by i nst al l i ng a headset wi t h
t he same O. D. on bot h cups and r est i ng a st r ai ght edge agai nst
t hose t wo di amet er s t o dr op t he angl e down t o t he bevel
pr ot r act or ( f i g. 255) . Readi ngs can t hen be t aken di r ect l y of f
t he scal e on t he bevel pr ot r act or .
MEASURI NG BOTTOMBRACKET DROP
Thi s i s a mor e compl i cat ed pr ocedur e. Measur e t he di amet er of
t he dummy hubs ( f i g. 256) and di vi de by 2 t o get t he Dummy Hub
Radi us ( DHR) . Measur e t he out er di amet er of t he bot t ombr acket
shel l ( f i g. 257) and di vi de by 2 t o get t he Bot t omBr acket Radi us
( BBR) .
Measur e t o t he t op of t he dummy hub as i t i s mount ed i n t he
V- bl ock wi t h t he pr oper bui l d- up or pedest al under i t ( f i g. 258) .
Cal l t hi s hei ght measur ement DHH. Measur e t o t he t op sur f ace of
t he bot t ombr acket shel l ( f i g. 259) . Cal l t hi s measur ement BBH.
Wi t h DHR, BBR, DHH and BBH t he exact bot t ombr acket dr op can
be f ound wi t h t he f ol l owi ng f or mul a.
Bot t omBr acket Dr op = ( DHH - DHR) - ( BBH BBR)
Tol er ances f or bot t ombr acket dr op can be pl us or mi nus . 025"
f or t op not ch cust ombui l t f r ames.
DOWN TUBE AND TOP TUBE ANGLE
The angl es of t he t op and down t ubes can be easi l y measur ed
whi l e t he f r ame i s mount ed ver t i cal l y. These measur ement s ar e of
l i t t l e i mpor t ance.
MOUNTI NG THE FORK ABOVE THE SURFACE PLATE
A St ar r et t #567 V- bl ock i s a conveni ent way t o mount a f or k
f or i nspect i on. The #567 has 3/ 8" NC t hr eaded hol es i n t he bot t om
whi ch al l ow t he V- bl ock t o be f ast ened t o a mor e massi ve pl at e
t hat can ser ve as a count er bal ance f or t he f or k. The f ol l owi ng
pi ct ur es show a #567 St ar r et t V- bl ock bei ng used.
MEASURING FORK RAKE
Cl amp t he s t eer i ng c ol umn i n t he V- bl oc k and us e t he uni ver s al
s ur f ac e gage t o l evel bot h s i des of t he c r own. Take a r eadi ng on
t he l ef t s i de of t he c r own ( f i g. 260) . Take a r eadi ng on t he
r i ght s i de of t he c r own ( f i g. 261) . I f t he r eadi ngs don' t mat c h,
t wi s t t he c ol umn i n t he V- bl oc k and t ake t he r eadi ngs agai n.
Repeat t hi s unt i l t he t wo r eadi ngs on t he c r own ar e t he s ame.
( The r eadi ngs c an al s o be t aken wi t h t he ver ni er hei ght gage. )
MEASURING RAKE ON THE FORK
Thi s i s a pr oc edur e al mos t i dent i c al t o t he meas ur i ng of
bot t om br ac ket dr op on a pr evi ous page. St ar t out by meas ur i ng t he
s t eer i ng c ol umn di amet er and di vi di ng by 2 t o get t he r adi us
( f i g. 262) . Cal l t hi s meas ur ement SCR. Meas ur e t he di amet er of
t he f r ont dummy hub and di vi de t o get t he r adi us ( f i g. 263. ) Cal l
t hi s meas ur ement DHR ( agai n) .
Measur e t he hei ght of t he st eer i ng col umn f r omt he t op of t he
sur f ace pl at e ( f i g. 264) . Cal l t hi s measur ement SCH. Measur e t he
hei ght of t he t op of t he dummy hub f r omt he sur f ace pl at e ( f i g.
265) . Cal l t hi s measur ement DHH ( agai n) .
Wi t h SCR, DHR, DHH, and SCH t he exact amount of r ake can be
det er mi ned wi t h t he f ol l owi ng f or mul a.
RAKE = ( DHH - DHR) - ( SCH - SCR)
Col d set t i ng t o change t he r ake can be done wi t h t he Par k
FFS- 1 and FT- 4 t ool s. Al t hough r ake coul d be checked on t he FT- 4,
f or t he sake of accur acy t he f or k shoul d be r emount ed on t he
sur f ace pl at e f or anot her check f or r ake. Tol er ances f or f or k
r ake can be pl us or mi nus . 025". ( For any quest i ons r egar di ng
what f or k r ake shoul d be, see pages 1- 7 t o 1- 10 of THE PATEREK
MANUAL. )
CHECKI NG FORK TWI ST WHI LE FORK I S MOUNTED HORI ZONTALLY
Take a hei ght r eadi ng on t he l ef t si de of t he cr own and cal l
t hat measur ement LCH ( f i g. 260) . Take a hei ght r eadi ng on t he
r i ght si de of t he cr own and cal l t hat measur ement RCH ( f i g. 261) .
Thi s i s an i dent i cal pr ocedur e t o t he one at t he t op of page 9- 20.
Take a hei ght r eadi ng on a poi nt of t he l ef t dr opout wher e t he
axl e woul d r est and cal l t hi s measur ement LDH ( f i g. 266) . Take a
hei ght r eadi ng on t he cor r espondi ng poi nt of t he r i ght dr opout and
cal l i t RDH ( f i g. 267) .
9- 22
The f ol l owi ng f or mul a wi l l t el l how much t wi st t her e i s i n t he
f or k.
I f LCH = RCH t hen LDH - RDH = TWI ST
Twi st may be expr essed as a posi t i ve or negat i ve number .
Accept abl e t ol er ances f or t wi st woul d be a di f f er ence of
015" bet ween LDH and RDH. Cor r ect i ng f or k t wi st can be done by
: ol d set t i ng wi t h Par k FT- 4 and FFS- 1. For mor e accur acy i n
ei nspect i ng f or f or k t wi st , r et ur n t o t he sur f ace pl at e.
MOUNTI NG THE FORK PERPENDI CULARLY TO THE SURFACE PLATE
For ot her oper at i ons
t he f or k wi l l have t o be
r ot at ed 90 degr ees i n t he
V- bl ock. To be sur e t hat
t he f or k i s exact l y
per pendi cul ar t o t he t abl e,
keep a machi ni st ' s squar e
t i ght agai nst t he cr own as
t he cl amp of t he V- bl ock i s
bei ng t i ght ened. I n t he
pi ct ur e t o t he r i ght ( f i g.
268) , t he ver ni er hei ght
gage i s bei ng used i nst ead
of a machi ni st ' s squar e.
CHECKI NG FOR TWI ST WHI LE FORK I S MOUNTED PERPENDI CULARLY TO PLATE
The f or k can be t est ed f or t wi st ver y easi l y at t hi s poi nt .
Si mpl y sl i de t he machi ni st ' s squar e al ong t he l engt h of t he bl ades
and obser ve any gaps bet ween t he bl ades of t he f or k and t he bl ade
of t he squar e. Thi s i s a much qui cker check t han t he ear l i er one.
I t t el l s not onl y when t her e i s t wi st , but al so t el l s when t her e
ar e any di f f er ences i n camber bet ween t he t wo f or k bl ades.
However , when t he f or k i s hel d per pendi cul ar t o t he pl at e i t i s
di f f i cul t t o quant i f y t wi st .
CHECKI NG DROPOUTS I N RELATI ON TO THE CENTERLI NE OF THE FORK
Thi s pr ocedur e i s
near l y i dent i cal t o
checki ng t he r ear t r i angl e
pl ane. The f i r st st ep i s
t o f i nd t he f or k cent er l i ne
( FCL) . Subt r act SCR f r om
SCH ( f i gs. 262 & 264) t o
get FCL. As wi t h t he r ear
t r i angl e, t ake a hei ght
r eadi ng t o t he i nsi de f ace
of t he l ower dr opout and
cal l t hat HI ( f i g. 269) .
Take a measur ement t o t he
out si de f ace of t he upper
dr opout and cal l t hat H2
( f i g. 270) . Measur e t he
t hi ckness of a dr opout
( f i g. 271) and cal l t hat T.
An al t er nat e way t o get t he measur ement s f or t he cent er l i ne of
t he f or k i s t o use a uni ver sal sur f ace gage and measur e t o t he
i nsi de f aces of bot h dr opout s ( f i gs. 272 & 273) . The r esul t s can
be t r ansf er r ed t o a st eel r ul e hel d ver t i cal l y i n a V- bl ock ( f i g.
245) .
Wi t h t hese val ues, t he exact or i ent at i on of t he f or k can be
det er mi ned.
Dr opout Spaci ng ( f or hub wi dt h) = H2 - H1 - T
Wi t h t he dr opout spaci ng ( DS) and t he FCL a t heor et i cal f or k
can be set up. The t heor et i cal f or k di agr amcan be f i l l ed i n wi t h
number s t hat woul d si mul at e a per f ect f or k wi t h t he gi ven DS and
FCL. Her e ar e t he f or mul as t o f i l l out t he di agr am.
Theor et i cal Hi = FCL - ( . 5 X DS)
Theor et i cal H2 = FCL + ( . 5 X DS) + T
9- 25
Her e i s t he di agr amt o f i l l out wi t h t he FCL, DS, Theor et i cal
H1, and Theor et i cal H2.
Now t ake t he act ual H1 and H2 f ound on t he sur f ace pl at e and
compar e t hemt o t he t heor et i cal H1 and H2 f i gur es. Thi s i s wher e
t he l ef t / r i ght al i gnment of t he f or k i s det er mi ned. I deal l y, H1
shoul d mat ch t heor et i cal H1 and H2 shoul d mat ch t heor et i cal H2.
I f t her e i s not a mat ch, col dset t i ng must be done t o cor r ect t hi s.
Tol er ances t hat mi ght be expect ed on a t op- not ch cust omf r ame
woul d be pl us or mi nus . 015". I MPORTANT: I f f or k t wi st and f or k
cent er l i ne ar e wi t hi n t ol er ances and bot h bl ades have mat chi ng
camber , but t he r i msi t s t o one si de i n t he f or k, one of t he
dr opout s i s f ur t her f r omt he cr own t han t he ot her . I f t hi s i s t he
case, one of t he dr opout s must be heat ed up and pul l ed out of t he
sl ot unt i l t he pr obl emi s el i mi nat ed.
A sur f ace pl at e i s by f ar t he most ver sat i l eet hod , f or t he
i nspect i on of bi cycl e f r ames. The t echni ci an i s not l ocked i n t o
i nspect i ng onl y bi cycl e f r ames. Ther e ar e many i nspect i on devi ces
manuf act ur ed f or t he sur f ace pl at e whi ch woul d al l ow i t t o be used
f or a mul t i t ude of ot her uses. Si ne bar s, gage bl ocks, j ack
scr ews, and i ndi cat or s can open up ot her hor i zons t he bui l der
pr obabl y never t hought of bef or e. Fur t her mor e, f or t he equi pment
f r eaks out t her e, Br own & Shar p, Mi t ut oyo, and St ar r et t make t ool s
and equi pment t hat have a ni cer l ook and f eel t han anyt hi ng i n t he
bi cycl e i ndust r y.
Thr ee r ef er ence books t o check out woul d be; 1- The Machi ni st ' s
Handbook,
a t hi ck gr een book avai l abl e i n most book st or es f or
about $40. 00,
2- The Machi ni st ' s Ready Ref er ence,
a smal l r i ngbound
book avai l abl e f or under $5. 00,
3- The St ar r et t Cat al ogue.
THE CORBETT METHOD
When cover i ng t he subj ect of pr eci si on measur i ng of bi cycl e
f r ames, one can not st op bl i ndl y wi t h one met hod. The out st andi ng
char act er i st i c of t he PATEREK met hod i s t o l ocat e on t he bot t om
br acket f aces, whi ch has been a st andar d pr ocedur e f or many year s.
The CORBETT: met hod l ocat es on t wo poi nt s on t he seat t ube and one
poi nt on t he head t ube. Thi s met hod i s qui t e si mpl e and t he
hol di ng f i xt ur e i s much l ess expensi ve t han t he one used i n t he
PATEREK met hod. ( Pl ease don' t t hi nk t hat t he aut hor i s bei ng
pr esumpt uous i n nami ng t hese t wo met hods af t er hi msel f and hi s
buddy. I t i s si mpl y bei ng done her e t o di f f er ent i at e bet ween t he
t wo met hods. ) Not e how t he bui l d- up under t he seat t ube i s
shi mmed up 1/ 16" mor e t han t he bui l d- up under t he head t ube. Thi s
al l ows f or t he di f f er ence i n t ubi ng di amet er s ( f i g. 274) .
Wi t h t he f r ame r est i ng on t he t hr ee par al l el s, al l t he same
measur ement s can be t aken t hat wer e t aken i n t he ear l i er met hod.
Seat and down t ube def l ect i on t r ansl at e i nt o bot t ombr acket t wi st
by t hi s met hod. Not e how t he i ndi cat or can be swept over t he
bot t ombr acket f aces t o show i f t her e ar e hi gh or l ow si des.
Measur i ng head t ube t wi st i s easy t oo. As i n t he PATEREK
met hod, si mpl y use t he i ndi cat or t o f i nd t he l ow spot of t he bor e
i n t he t op ( f i g. 278) and bot t om( f i g. 279) of t he head t ube.
Si nce t he seat t ube i s unquest i onabl y par al l el t o t he pl at e, any
var i at i on i mmedi at el y t r ansl at es i nt o head t ube t wi st . Head cups
of f er a ni ce pr eci si on bor e t o l ocat e on.
I n f i ndi ng t he r el at i onshi p bet ween t he pl anes of t he f r ont
and r ear t r i angl es, t he f l i p- f l op met hod i s used. Fi r st t he
i nsi de f ace of t he r i ght dr opout i s checked wi t h t he hei ght gage
( f i g. 280) . Then t he f r ame i s f l i pped over and t he i nsi de f ace of
t he l ef t dr opout i s checked ( f i g. 281) . Thi s gi ves a ver y exact
measur ement because when t he f r ame i s f l i pped l i ke t hi s, t he er r or
i s doubl ed and easi er t o spot . I deal l y, bot h i nsi de f aces shoul d
gi ve t he same r eadi ng.
For k r ake can be checked by mount i ng t he f or k i n a V- bl ock and
r est i ng i t on anot her V- bl ock t o gai n hei ght f r omt he sur f ace
pl at e. Fi r st t he l ef t si de of t he dummy hub i s i ndi cat ed. Then
t he r i ght si de i s i ndi cat ed ( f i g. 282) . Twi st t he st eer i ng col umn
t i l l bot h r eadi ngs ar e t he same. A r eadi ng i s t hen t aken t o get
t he dummy hub hei ght ( DHH) . Anot her r eadi ng i s t aken t o get t he
st eer i ng col umn hei ght ( SCH) . Subt r act i ng t he t wo hei ght s and
r adi i wi l l gi ve r ake. ( Not e t he use of t he VAR f or k cr own r ace
sl i de hammer as a count er bal ance. )
The ni ce f eat ur e of THE CORBETT METHOD i s t hat t he f or k never
l eaves t he V- bl ock af t er i t i s i ndi cat ed i n. Fl i p t he V- bl ock 90
degr ees and check f or t wi st wi t h a machi ni st ' s squar e ( f i g. 283) .
The t i ps can now be checked i n r el at i on t o t he cent er l i ne. Take
a hei ght r eadi ng on t he i nsi de f ace of t he l ef t dr opout ( f i g.
284) . Don' t r emove t he f or k f r omt he V- bl ock. Fl i p t he whol e
assembl y and t ake a r eadi ng on t he i nsi de f ace of t he r i ght
dr opout ( f i g. 285)
286 287
The opt i on of measur i ng f or k bl ade l engt h was not of f er ed i n
t he PATEREK met hod. I n t he CORBETT met hod, whi l e t he f or k i s
st i l l mount ed i n t he V- bl ock, i t i s t ur ned ver t i cal l y and t he t i ps
ar e measur ed i n r el at i on t o t hei r di st ance f r omt he sur f ace pl at e.
Thi s r equi r es a way t o mount an i ndi cat or about 15" up f r omt he
sur f ace pl at e. ( f i gs. 286 & 287)
Mount i ng t he f r ame ver t i cal l y above t he sur f ace pl at e i s done
al most i dent i cal l y i n bot h met hods. I n f i gur e 288, head t ube
angl e i s bei ng measur ed. Not e how t he measur ement i s bei ng
l ocat ed on t he out er di amet er of a hi gh qual i t y headset . Al so,
not e how t he angl e i s bei ng dr opped down t o meet t he pr ot r act or .
I n f i gur e 289The hei ght of t he dummy axl es i s bei ng measur ed i n
t he same way as t he PATEREK met hod. I n f i gur e 290, a Campagnol o
f i xed cup i s used t o f i nd bot t ombr acket hei ght . ( Si nce t he Campy
cup i s exact l y 36mmacr oss t he f l at s, 18mmi s subt r act ed f r omt he
hei ght measur ement . )
THE FRAME ALI GNMENT SYSTEM- THE NEWENGLAND CYCLI NG ACADEMY
Ther e ar e not many pr eci si on measur i ng syst ems put out
st r i ct l y f or t he pur pose of bi cycl e f r ame i nspect i on. The Fr ame
Al i gnment Syst emi s one def i ni t el y wor t h ment i oni ng. I t s f i xt ur es
ar e of t he hi ghest qual i t y, yet si mpl e and easy t o use. The
syst emconsi st s of a bed wi t h a swi ng ar mand bot t ombr acket
cl amp at t ached, a dummy hub gage, a j ack and a cheat er bar . A
uni ver sal sur f ace gage, Campagnol o H t ool s, Campagnol o 724/ 1 &
724/ 2 t ool s, and Mar chet t i and Lange head t ube ext ensi ons ar e al so
used wi t h t hi s syst em. ( f i g. 291)
N. E. C. A. r ecommends spr ayi ng an al l pur pose l ubr i cant ( f i g.
292) on t he pr eci si on gr ound sur f ace and l i ght l y honi ng i t ( f i g.
293) t o r emove any bur r s whi ch may devel op f r omany r ough use.
9- 31
As r equi r ed wi t h any pr eci si on measur i ng of bi cycl e f r ames,
t he bot t ombr acket shel l must be f aced. Si nce t he Fr ame Al i gnment
syst emhas been desi gned t o accommodat e Campagnol o #724/ 1 & 724/ 2
i nser t s ( f i g. 294) , t he bot t ombr acket shoul d be f aced wi t h
Campagnol o t ool #725. Af t er f aci ng, t he bot t ombr acket shel l
( wi t h i nser t s st i l l i n pl ace) can be l ower ed r i ght ont o t he bot t om
br acket cl amp ( f i g. 295) .
Si nce t he bot t ombr acket cl amp r ot at es on pr eci si on bear i ngs,
t he f r ame can be easi l y r ot at ed so t hat any f r ame member can be
di r ect l y above t he pr eci si on gr ound bed ( f i g. 296) . Not e how t he
j ack can be put under a t ube t hat l i es above t he bed. Thi s i s
done f or t wo r easons: 1. The j ack can be used as a gage by passi ng
i t under di f f er ent l ocat i ons al ong t he t ube and checki ng f or
cl ear ance; 2. The j ack can pr ovi de suppor t f or cer t ai n col d
set t i ng oper at i ons. ( Not e how t appi ng t he f i nger i n f i gur e 297
det er mi nes i f t he j ack i s t ouchi ng t he head t ube. )
9- 32
To pr ovi de addi t i onal suppor t and st abi l i t y, t he swi ng ar mcan
be al i gned wi t h t he seat t ube and a f i t t i ng i nser t ed i nt o t he t op
of t he seat t ube ( f i g. 298) . I n f i gur e 299t he swi ng ar mas wel l
as t he j ack ar e i n pl ace whi l e t he head t ube i s bei ng measur ed f or
t wi st .
N. E. C. A. f ul l y r ecommends col d set t i ng whi l e t he f r ame i s
mount ed i n t he Fr ame Al i gnment Syst em. I n f i gur e 300, t he cheat er
bar i s bei ng used t o r ai se t he head t ube t o put i t i n t he same
pl ane as t he seat t ube. I n f i gur e 301, t he head t ube i s bei ng
pushed downwar d t o accompl i sh t he same t hi ng but i n t he opposi t e
di r ect i on.
9- 33
A uni que and ver y necessar y par t of t he Fr ame Al i gnment Syst em
i s t he Dummy Hub Gage. Thi s devi ce si mul t aneousl y f i nds t he
t heor et i cal cent r al pl ane of t he f r ame and t he t heor et i cal
l ocat i on of t he i nsi de f aces of t he dr opout s. N. E. C. A. ' s Bi l l
Far r el l l ocat es t he cent r al pl ane of t he f r ame cl ose t o t he bot t om
br acket ( f i g. 302) . I n f i gur e 303 he shows t he i nt er changeabl e
st uds t hat si mul at e 100mm, 120mm, and 126mmhub wi dt hs.
The Dummy Hub Gage can be used t o det er mi ne whet her t he r ear
dr opout s ar e equi di st ant f r omt he cent er l i ne of t he f r ame ( f i g.
304) . I f t hey ar e out of l i ne, t hey can be col d set i nt o pl ace.
Not e how t hi s can be done by hand ( f i g. 305) . A gr eat deal of
f or ce i s not al ways necessar y f or col d set t i ng pr ocedur es.
To check t r acki ng bet ween t he f or k and t he r est of t he f r ame,
a f or k can be i nst al l ed wi t h a hi gh qual i t y headset . The f r ame
and f or k can t hen be put i n pl ace on t he bot t ombr acket cl amp.
The dummy hub gage can t hen be set t o t he seat t ube cl ose t o t he
bot t ombr acket . A r eadi ng can t hen be t aken at t he f r ont
dr opout s ( f i g. 306) .
Anot her component of The Fr ame Al i gnment Syst emi s t he f or k
i nspect i on f i xt ur e. Thi s f i xt ur e i s not avai l abl e t o
f r amebui l der s and i s onl y used at N. E. C. A. I t cl amps t o t he bed
and hol ds a f or k so t hat i t can be checked i n r ef er ence t o t he
pr eci si on gr ound sur f ace. The f i r st st ep i s t o det er mi ne t he
cent er l i ne of t he f or k by set t i ng t he Dummy Hub Gage t o t he
st eer i ng col umn ( f i g. 307)
9- 35
St ep t wo i n i nspect i ng t he f or k i s t o squar e t he bl ades wi t h
t he pr eci si on gr ound sur f ace. Thi s i s done by hol di ng t he st uds
of t he Dummy Hub Gage t i ght l y agai nst t he t op backsi de sur f aces of
t he f or k bl ades whi l e t i ght eni ng t he cl amp ( f i g. 308) . St ep t hr ee
i s t o move t he Dummy Hub Gage t o t he dr opout s and see how easi l y
i t sl i des i nt o pl ace ( f i g. 309) . Col d set t i ng i s t hen done
accor di ngl y.
For mor e i nf or mat i on on The Fr ame Al i gnment Syst em, wr i t e t o
t he New Engl and Cycl i ng Academy. Mai l i ng i nf or mat i on can be f ound
i n t he r esour ce sect i on of t hi s book.
I n t he ar ea of pr eci si on measur i ng, we have some r eal l y
accur at e devi ces nowadays. Tol er ances i n t housandt hs of an i nch
ar e not hi ng compar ed t o what i s on t he mar ket now. Some bi cycl e
manuf act ur er s ar e now adver t i si ng t hat t hey use i nspect i on devi ces
t hat ar e accur at e t o +. 00001". Thi s i s mi sl eadi ng t o t he consumer
and t he i ndependent f r amebui l der shoul d be awar e of t he t act i cs
used by some of t he l ar ger compani es. I t i s t ot al l y unr eal i st i c
and assi ni ne t o t r y t o bui l d bi cycl e f r ames t o t ol er ances i n t he
r ange of . 00001". To st r ess a poi nt , a f or k coul d be mount ed i n
t he hor i zont al pl ane and i ndi cat ed t o t he near est hundr ed
t housandt h of an i nch. A bal l poi nt pen coul d t hen be gent l y
r est ed on t he dr opout s and t hey wi l l mor e t han l i kel y dr op at
l east . 00001" and t ake t he f or k out of t ol er ance moment ar i l y.
When r eadi ng t hese ads, t he r eader shoul d ask hi msel f i f t he ad
says t hat t he i nspect i on devi ce i s accur at e t o +. 00001" or i s t he
f r ame f al l i ng wi t hi n t hose t ol er ances. Those ar e t wo t ot al l y
di f f er ent i deas. A per son can measur e t he f i sh he caught at Lake
Mi nnet onka l ast summer wi t h a machi ne accur at e t o . 00001" but t hat
does not necessar i l y mean t hat f i sh t ast es bet t er because i t was
measur ed on i ncr edi bl y accur at e equi pment .
A NUMEREX machi ne i s shown i n f i gur es 310 & 311. Thi s
par t i cul ar uni t i s accur at e t o +. 00001". I t i s excel l ent f or
i nspect i ng B- 1 Bomber par t s or Space Shut t l e par t s. I t oper at es
wi t h a pr obe t hat measur es coor di nat es on X, Y, & Z axes.
( Woul dn' t i t be t empt i ng t o put t hi s i n my next cat al ogue and make
some sor t of out l andi sh cl ai m?)
The CORDAXIV ( f i g. 312) i s al so a coor di nat e measur i ng
machi ne t hat measur es al ong X, Y, & Z axes. I t t oo, has accur acy
t o . 00001". Look at t he l ow qual i t y f or k t hat i s mount ed i n t he
CORDAX. J ust because t hi s l ow qual i t y f or k was measur ed wi t h a
CORDAX doesn' t make i t any bet t er .
9- 37
The Mi t ut oyo Hei ght Mast er ( f i g. 313) i s one of t he most
sensi t i ve hei ght gages avai l abl e t oday. I t i s al so accur at e t o
. 00001". Anyone wor ki ng on co
m
muni cat i ons sat el l i t e par t s shoul d
def i ni t el y have one.
One of t he si l l i est pi ct ur es I ' ve seen i n a nat i onal bi cycl e
magazi ne was of a f r amebui l der who was wor ki ng on one of t he
Ol ympi c f unny bi kes. He had i ncr edi bl y sensi t i ve i nspect i on
equi pment and was wear i ng a pai r of whi t e gl oves! I n our ef f or t s
t o t ur n out bet t er pr oduct s, l et ' s not l ose t ouch wi t h r eal i t y.
As we l eave t hose f r amebui l der s and f l i nt l ock maker s of yest er year
i n t he dust , l et ' s not gi ve t he f r amebui l der s of t omor r ow
somet hi ng t o l augh about . Choose a r eal i st i c set of t ol er ances
and t r y t o mai nt ai n t hem.
PAI NTI NG
Thi s sect i on of THE PATEREK MANUAL wi l l deal wi t h pai nt i ng
pr epar at i on- maski ng- pr i mi ng- col or coat s- pl at i ng- t ouch- up,
pai nt suppl i es- and pai nt i ng equi pment . Due t o t he f act t hat t he
aut hor i s hi ghl y f ami l i ar wi t h t he DuPont - 3M- and Bi nks pr oduct
l i nes. t her e wi l l be some obvi ous l eani ngs i n t hose di r ect i ons.
Ther e ar e some hi ghl y t echni cal ar eas t hat wi l l not be cover ed
i n t hi s sect i on because t he DuPont Ref i ni sh Shop Manual does such
a good j ob. I t woul d be advi sabl e t o pur chase a copy of t hi s
publ i cat i on f r oma l ocal DuPont deal er , dr i l l f our ext r a hol es i n
t he l ef t mar gi n. and cl i p i t i n t hi s sect i on of t he book. I t
answer s such quest i ons as how pr obl ems ar e caused i n pai nt i ng and
how t hey ar e r emedi ed. ( DuPont i s l i st ed i n t he r esour ce sect i on
of t hi s book. )
I t i s i mpor t ant t o add at t hi s t i me t hat pai nt i ng i s pr obabl y
t he pr ocess i n t he manuf act ur i ng of bi cycl e f r ames t hat i s most
hazar dous. Not onl y does i t pose t he t hr eat of r espi r at or y
damage. ki dney f ai l ur e, and even neur ol ogi cal di sor der s i f
cont i nual exposur e t o t he f umes i s exper i enced, but t he r i sk of
f i r e i s al so ext r emel y hi gh. These f act or s must be consi der ed
bef or e st ar t i ng a pai nt i ng busi ness and al l possi bl e pr ecaut i ons
must be t aken t o l essen t hese hazar ds.
Bef or e cont i nui ng t her e ar e some basi c r ul es t o r emember
bef or e at t empt i ng t o pai nt :
1- - Don' t mi x di f f er ent br ands of pai nt pr oduct s.
2- Don' t wear wool , f l annel - or any ot her f uzzy
cl ot hi ng t hat mi ght cr eat e a pr obl emwi t h l i nt .
3- Don' t pai nt when you' r e t i r ed or f r ust r at ed.
4- Spar e no expense i n obt ai ni ng and i nst al l i ng pr oper
f i r e ext i ngui shi ng and vent i l at i on equi pment .
5- Al ways use a r espi r at or of adequat e desi gn.
6- When i n doubt , f ol l ow t he di r ect i ons on t he back of
t he cans.
DO NOT SMOKE WHI LE PAI NTI NG, DO NOT ALLOWOTHERS ' I t ) SMOKE WHI LE
YOU ARE PAI NTI NG AND DO NOT ALLOWAN OPEN FLAME I N THE ROOM AT ANY
TI ME! ! ! ! !
11- 1
PAI NTI NG AND THE LAW
Bef or e set t i ng up a pai nt i ng syst em, t her e ar e a f ew i t ems
t hat must be checked out . Due t o t he f act t hat spr ay pai nt i ng i s
a def i ni t e heal t h and f i r e hazar d, t her e may be some maj or
st umbl i ng bl ocks bef or e st ar t i ng out .
Fi r st of al l , check t he zoni ng r equi r ement s t he ci t y may have
r egar di ng spr ay pai nt i ng. Si nce a spr ay pai nt i ng oper at i on woul d
emi t pol l ut i ng and even poi sonous f umes, i t may be cl assi f i ed as
an i ndust r i al busi ness r at her t han a si mpl e commer ci al busi ness.
Such a cl assi f i cat i on may r equi r e t hat t he oper at i on be l ocat ed i n
an i ndust r i al par k or i ndust r i al l y zoned ar ea of t he ci t y.
Fai l ur e t o f ol l ow ci t y zoni ng such as t hi s woul d be an i nvi t at i on
f or a shut down by t he ci t y.
I f t her e ar e ot her empl oyees wor ki ng i n t he shop wher e t he
pai nt i ng i s t o t ake pl ace, The Nat i onal I nst i t ut e of Occupat i onal
Saf et y Heal t h ( N. I . O. S. H. , f or mer l y known as O. S. H. A. )
r egul at i ons must be checked out . N. I . O. S. H. has ver y st r i ct
r equi r ement s whenever t her e i s a t hr eat t o t he saf et y or heal t h of
any empl oyee i n any busi ness. Spr ay pai nt i ng i s one act i vi t y t hat
i s under t i ght cont r ol .
A cal l t o t he l ocal f i r e depar t ment woul d be a good i dea.
They wi l l know al l of t he or di nances r egar di ng f i r e saf et y and
pr event i on. Many ci t i es may r equi r e a pai nt shop t o be l ocat ed on
a concr et e f l oor or i n a ci nder bl ock r oom. Many muni ci pal i t i es
f or bi d or at l east di scour age spr ay pai nt i ng i n a wood f r ame
st r uct ur e wi t hout t he pr oper modi f i cat i ons.
The i nsur ance company shoul d be not i f i ed. Many i nsur ance
compani es wi l l not pay f or damages f r omf i r es i f t hey ar e not
not i f i ed ahead of t i me of any change of st at us of t he i nsur ed.
They must be i nf or med of any f i r e or heal t h hazar ds t hat may be
posi ng a t hr eat . Looki ng t hr ough t he i nsur ance pol i cy paper s may
yi el d t he necessar y i nf or mat i on bei ng sought . A wor d of war ni ng -
commer ci al spr ay pai nt i ng may i ncr ease i nsur ance pr emi ums
subst ant i al l y!
Peopl e who own busi nesses i n r ur al set t i ngs ar e usual l y under
much l ess r egul at i on.
I f al l of t he above i t ems have been t hor oughl y i nvest i gat ed,
i t ' s t i me t o st ar t set t i ng up.
11- 2
1
THE PAI NTI NG SYSTEM
The pai nt i ng syst emi s made up of f our maj or par t s; 1- t he
boot h, 2- t he gun, 3- t he compr essor , 4- t he br eat hi ng syst em. Bel ow
i s an i l l ust r at i on of an i deal bi cycl e f r amepai nt i ng syst em.
41130 THE PAINTING SYSTEM
THE BOOTH
When bui l di ng a boot h, t hr ee mai n consi der at i ons must be
made i n i t s desi gn- 1) t he shel l , 2) l i ght i ng, 3) vent i l at i on.
THE SHELL
The shel l of t he boot h shoul d be made of a
r el at i vel y heavy gage of sheet met al . Never const r uct a
shel l out of wood or car dboar d! A saf e pai nt i ng boot h
must be abl e t o cont ai n a f l ash f i r e l ong enough t o
al l ow t he pai nt er t o gr ab a f i r e ext i ngui sher . Thi s
woul d be di f f i cul t wi t h a wooden boot h and i mpossi bl e
wi t h a car dboar d boot h. A shel l made of combust i bl e
mat er i al woul d st ar t t o bur n al most i mmedi at el y and need
t o be ext i ngui shed i t sel f . A commer ci al l y made boot h
wi t h an i ndust r i al st r engt h shel l can be pur chased f or
sever al t housand dol l ar s ( f i g. 314) . A l ess subst ant i al
boot h can be made by a l ocal pl umbi ng and heat i ng out f i t
f or l ess t han $200, 00.
11- 3
Anot her i mpor t ant r equi r ement f or a boot h shel l i s
t o be bi g enough t o compl et el y sur r ound any i t emt hat
wi l l be pai nt ed i n i t . A boot h 46" X 48" X 48" i s l ar ge
enough t o pai nt even a 27" f r ame. The 46" di mensi on
wi l l al l ow t he sheet met al wor ker t o ut i l i ze t he f ul l 4
f eet of a sheet of st eel i n t wo di r ect i ons and al l ow f or
seams on t he 46" si de.
LI GHTI NG
Good l i ght i ng i s of t he ut most i mpor t ance i n
pr oduci ng good pai nt j obs. I t i s necessar y t o be abl e
t o see t he f i nest det ai l whi l e pai nt i ng and good
l i ght i ng wi l l make t hi s possi bl e. I t i s di f f i cul t t o
det ect a r un f or mi ng or t he pr esence of or ange peel i n a
poor l y l i t boot h. I ncandescent bul bs ar e pr ef er r ed, as
t hey do not t end t o pr oduce spar ks t he way f l uor escent
bul bs can. I f f l uor escent bul bs ar e used, t hey must be
mount ed out si de t he boot h wi t h gl ass or pl ast i c sheet s
or wi ndows keepi ng t hemf r ombei ng i n cont act wi t h t he
pai nt f umes. I ncandescent bul bs may be put i n i mmedi at e
cont act wi t h pai nt f umes wi t hout t he f ear of causi ng
f i r es. Use 3 or mor e 200 wat t bul bs i n a boot h bi g
enough t o pai nt a bi cycl e f r ame.
VENTILATION
The boot h shoul d be vent i l at ed f r omt he r ear , and
pr ef er abl y f r omt he upper hal f of t he boot h. By
vent i l at i ng f r omt he r ear , t he f an wi l l push t he har mf ul
f umes out t he back whi l e at t he same t i me pul l i ng f r esh
ai r past t he oper at or and i nt o t he boot h. Thi s ai r f l ow
i s ver y i mpor t ant .
11- 4
A f an must be mount ed i n t he back of t he boot h t o
pr ovi de t he necessar y ai r f l ow. Choosi ng t he cor r ect
t ype of f an i s i mpor t ant t o l essen f i r e hazar ds.
El ect r i c mot or s pr oduce spar ks and most el ect r i c mot or s
ar e open at t he ends. By l ooki ng i n t he ends whi l e t he
mot or i s r unni ng, t he spar ks can be pl ai nl y seen. These
spar ks ar e t he f i r e hazar ds. Pai nt f umes t hat come i n
cont act wi t h t hese spar ks can easi l y i gni t e and cause a
f l ash f i r e. Some mot or s ar e seal ed so t hat t he spar ks
t hey pr oduce can not come i n cont act wi t h any pai nt
f umes. Thi s i s t he t ype of mot or t o choose f or a
pai nt boot h. Wi t h l uck a f an wi t h a seal ed mot or can be
f ound. Such a f an can be mount ed di r ect l y i n t he openi ng
at t he back of t he boot h. Thi s woul d be t he si mpl est
way t o mount a f an. A saf er way t o mount a f an woul d be
t o mount a squi r r el cage f an ( f i g. 315) wi t hi n t he duct
wor k comi ng of f t he back of t he boot h. The squi r r el
cage f an can t hen be r un by a mot or out si de t he duct
wor k whi ch doesn' t come i n cont act wi t h pai nt f umes.
Most muni ci pal i t i es wi l l r equi r e a f i l t r at i on syst em
t o r emove t he par t i cul at es f r omt he f umes bef or e t hey
ar e r el eased i nt o t he at mospher e. On t he pr evi ous page,
t he f i l t er s can be pl ai nl y seen i n t he back of t he
commer ci al boot h. A f ur nace f i l t er can be i nst al l ed i n
t he smal l cust om- made boot h. Make sur e t he f an i s
power f ul enough t o pul l a st eady ai r f l ow r i ght t hr ough
t he f ur nace f i l t er !
A f i nal i mpor t ant i t emf or any pai nt boot h i s t o
have duct wor k or a hood t hat wi l l di r ect f umes t o a saf e
ar ea. Do not bl ow pai nt f umes wher e passer sby may
i nhal e t hem.
11- 5
THE GUN
The gun i s one of t he most i mpor t ant pi eces of equi pment
i n pai nt i ng. Most peopl e who wi sh t o st ar t pai nt i ng bi cycl e
f r ames f i nd i t har d t o choose t he cor r ect pai nt i ng gun and
cup. Her e ar e a f ew cr i t er i a t o go by t o make t he deci si on
easi er .
1. Make sur e t he gun i s l ar ge enough t o handl e t he j ob. An
ai r br ush ( f i g. 316) , i s a scal ed down ver si on of a pai nt
gun. Some peopl e may have a t endency t o buy an ai r br ush
because i t i s smal l and so ar e bi ke f r ames. An ai r br ush
i s f or ver y f i ne det ai l wor k and shoul d onl y be used as
an ext ensi on of what can al r eady be done wi t h t he
exi st i ng pai nt gun. A ski l l ed t echni ci an can do
somet hi ng as f i ne as pi nst r i pi ng wi t h an ai r br ush. I f
an ai r br ush wer e used t o pai nt a whol e f r ame, I t woul d
have t o be r ef i l l ed about 4 t i mes because t he cup
capaci t y i s so smal l . An ai r br ush shoul d not be
pur chased unt i l ski l l and t echni que ar e devel oped wi t h a
r egul ar gun and cup.
2. Make sur e t he gun i s smal l enough t o handl e t he j ob.
Many guns ar e qui t e l ar ge and heavy. A l ar ge gun such
as Bi nks model s 7, 26, 18, 62, 370, or 69 ar e qui t e
l ar ge and woul d be unwi el dy i n a smal l pai nt boot h such
as t he one descr i bed ear l i er . ( A Bi nks model 7 i s shown
i n f i g. 318. ) These guns have qui t e a l ar ge cup ( 1
quar t ) , whi ch i s mor e t han i s ever necessar y f or
pai nt i ng a f r ame. The onl y t i me any of t hese guns woul d
be r ecommended woul d be f or pr oduct i on wor k wher e many
f r ames woul d be pai nt ed t he same col or . I n t hi s way t he
excess l ef t over at t he bot t omof t he cup i s not wast ed
as much. Anot her t i me a l ar ger gun coul d be used woul d
be f or pr i mi ng a r un of bi kes. Anot her di sadvant age of
a l ar ge gun i s t hat t he f an pat t er n may not be abl e t o
be adj ust ed down smal l enough t o do a bi ke f r ame
ef f i ci ent l y. The pr i mar y consi der at i on wi t h a l ar ge gun
t hen t ur ns out t o be "wast e. "
3. Set t l e onl y f or st ai nl ess st eel needl e val ves and
or i f i ces wi t h t ef l on seal s. Gasket s shoul d be made of
l eat her or r ubber . Some cheaper guns wi l l use al umi num
i n pl ace of some st ai nl ess par t s and pl ast i c i n pl ace of
ot her met al par t s. A cheaper gun wi t h al umi numcast i ngs
and pl ast i c par t s wi l l wear out qui ckl y and del i ver a
poor l y f or med f an pat t er n af t er onl y a shor t per i od of
t i me; al umi numcups ar e qui t e accept abl e however .
11- 6
The gun and cup ( t he cup i s of t en pur chased separ at el y)
t hat best f i t t hese cr i t er i a ar e usual l y r ef er r ed t o as a
"t ouch- up gun. " Bi nks, DeVi l bus, and Shar pe al l make a
t ouch- up gun. They al l f i t easi l y i nt o t he pal mof t he hand,
have t he necessar y st ai nl ess and t ef l on par t s and hol d
appr oxi mat el y 8 oz. of pai nt , whi ch i s about enough t o pai nt
one f r ameset .
The aut hor ' s choi ce was a Bi nks #115 t ouch- up gun ( shown
i n f i g. 317) . I t was easy t o obt ai n l ocal l y and was hi ghl y
r ecommended by anot her pai nt er .
The pr i nci pl es whi ch make t he pai nt gun oper at e ar e
si mpl e and easy t o under st and. Ai r r ushes t hr ough a
hor i zont al t ube and passes over t he t op of a ver t i cal t ube
whi ch i s submer ged i n t he pai nt . Thi s ai r f l ow causes a
r educt i on of pr essur e at t he t op of t he ver t i cal t ube. At
t hi s poi nt , t he onl y t hi ng t hat can happen i s f or t he pai nt
t o r i se i n t he ver t i cal t ube. When t he pai nt r eaches t he t op
of t he ver t i cal t ube, i t i s caught i n t he ai r f l ow at t he
f r ont of t he hor i zont al t ube. The ai r f l ow t hen f or ces t he
pai nt f or war d. Ther e i s a ver y si mpl e devi ce t hat ar t
st udent s once used, consi st i ng onl y of t hese t wo pi eces of
t ubi ng- - a mout h- oper at ed spr ay gun ( i l l . 131) Per f ume
spr ay bot t l es ar e anot her var i at i on of t he same pr i nci pl e;
t hey have a suppl y of compr essed ai r ( t he bul b) and a nozzl e
t o spr ead out t he mi st . Fr omt hi s poi nt , f ur t her
embel l i shment s can be added: ai r pr essur e cont r ol , f an si ze
cont r ol , and f an r ot at i on cont r ol . Add t he cor r ect si ze of
cup, necessar y st ai nl ess st eel and t ef l on par t s, and a
compr essed ai r suppl y and "Voi l a! , " you have a gun sui t abl e
f or pai nt i ng a bi cycl e f r ame.
11- 7
L1 .1 31 : Mouth operated spray gun (not for use with automotive paints)
MAKI NG THE NECESSARY TEMPORARY ADJ USTMENTS
The #115 gun, as wel l as most ot her t ouch- up guns, has
f our t empor ar y adj ust ment s. They ar e t empor ar y i n t hat t hey
can be made wi t hout t ool s and can be made i n onl y seconds
dur i ng t he mi ddl e of a pai nt i ng sessi on. These f our
adj ust ment s ar e: 1) f an cont r ol , 2) f an r ot at i on, 3) f l ui d
cont r ol , and 4) ai r pr essur e cont r ol at t he compr essor .
1. FAN CONTROL- Adj ust i ng t he f an i s qui t e si mpl e. On t he
f r ont l ef t hand si de of t he gun i s a knur l ed knob ( ar r ow
i n f i g. 319) . Tur ni ng t hi s knob cl ockwi se gi ves a
smal l er f an. Tur ni ng i t count er - cl ockwi se gi ves a
l ar ger , f l at t er f an. A ver y smal l f an i s pr ef er r abl e i n
bi cycl e f r ame pai nt i ng because t ube di amet er s ar e
r el at i vel y smal l ar eas t o pai nt and a smal l er f an
r educes wast e due t o over spr ay.
11- 8
321
2. FAN ROTATI ON- Adj ust i ng f an r ot at i on i s al so qui t e
si mpl e and i s done on a per sonal pr ef er ence basi s. The
nozzl e on t he f r ont can be r ot at ed by l ooseni ng t he
l ar ge knur l ed r i ng on t he f r ont of t he gun ( whi t e ar r ow
i n f i g. 320) , and t wi st i ng t he t wo st ubs t hat pr ot r ude
f r omt he nozzl e ( bl ack ar r ow i n f i g. 320) . Af t er t he
nozzl e i s r ot at ed t o t he cor r ect posi t i on, t he r i ng can
be t i ght ened agai n. ( Do not over t i ght en! ) Rot at i ng t he
nozzl e i s done f or one mai n r eason- - by doi ng so, t he gun
may be hel d so t hat t he f l at t ened f an i s al i gned wi t h
t he obj ect bei ng pai nt ed. I n ot her wor ds, t he pai nt er
does not have t o t i l t t he gun so much t o get good
cover age whi l e pai nt i ng.
3. FLUI D CONTROL- The amount of pai nt bei ng suppl i ed t o t he
nozzl e of t he gun must be bal anced wi t h t he pr essur e
goi ng t o t he nozzl e. Thi s adj ust ment can be made wi t h
t he knur l ed knob at t he back of t he Bi nks #115 gun
( ar r ow i n f i g. 321) . Tur n i t cl ockwi se f or mor e f l ui d,
count er - cl ockwi se f or l ess f l ui d. I t i s best t o st ar t at
l ow f l ui d set t i ng and wor k up t o t he cor r ect set t i ng.
Not enough f l ui d can r esul t i n not bei ng abl e t o cover
l ar ge ar eas wel l and can pr oduce an "or ange peel "
ef f ect . Too much f l ui d wi l l cause r uns t o occur much
mor e easi l y. Tr y t o get a comf or t abl e set t i ng i n t he
mi d- r ange. Expect t o adj ust f l ui d set t i ngs as of t en as
t wo or t hr ee t i mes i n one pai nt i ng sessi on.
4. PRESSURE CONTROL AT THE COMPRESSOR- Di r ect i ons f or
di f f er ent pai nt pr oduct s wi l l cal l f or var yi ng del i ver y
pr essur es. Met al l i cs of t en cal l f or mor e pr essur e t han
sol i ds. Pr i mer s mi ght cal l f or even l ess pr essur e t han
sol i ds. Look at t he di r ect i ons on t he can t o see what
pr essur e i s r ecommended f or t hat par t i cul ar pai nt . Even
so, t hese ar e onl y est i mat es, and var i at i ons i n
t emper at ur e and humi di t y may necessi t at e al t er i ng t hese
specs. The pr essur e can be set qui t e easi l y by t ur ni ng
i n t he scr ew at t he di aphr agmf or mor e pr essur e and
t ur ni ng out t he di aphr agmscr ew f or l ess pr essur e. The
di aphr agmwi l l have a pr essur e gage mount ed by i t t o
i ndi cat e l i ne pr essur e ( f i g. 323) . I f t he compr essor
does not have a di aphr agmwi t h a gage, an i n- l i ne add- on
ki t can be pur chased f or about $25. 00 ( f i g. 322) .
GUN MAI NTENANCE
Four t hi ngs must be done t o t he gun on a r egul ar basi s:
1) f l ushi ng t he gun at t he end of a pai nt i ng sessi on or when
changi ng col or s, 2) r epl aci ng wor n needl e val ves, 3) t ot al
br eakdown and cl ean- up, 4) r epl acement of seal s and seat s.
1. When a pai nt i ng sessi on i s f i ni shed or when changi ng
col or s, t he gun and cup must be f l ushed wi t h cl ean
sol vent . Lacquer t hi nner i s sui t abl e f or most gun
cl eani ng pr ocedur es. Dump t he excess pai nt i n a pr oper
wast e cont ai ner . Scr ub t he gun and cup wi t h sol vent and
a t oot hbr ush. ( Pepsodent Toot hbr ushes wi l l not mel t i n
l acquer t hi nner . ) Now, j ust as i f pai nt i ng, shoot
sol vent t hr ough t he gun f or about 30 seconds. Dump t he
sol vent , whi ch i s now qui t e di scol or ed, i nt o a pr oper
wast e cont ai ner . Repeat t hi s wi t h cl ean sol vent . Thi s
may have t o be r epeat ed t wo or t hr ee t i mes unt i l onl y
cl ean mi st comes out of t he f r ont of t he nozzl e.
11- 10
324
325a
WARNI NG: The cl eani ng sol vent can st ay t r apped i n some
of t he cavi t i es of t he gun f or sever al days. When next
shoot i ng a col or or cl ear coat , spr ay t he pai nt f or
about 15 seconds t o cl ean out any sol vent r esi due bef or e
shoot i ng pai nt ont o t he wor k sur f ace.
2. Ther e ar e some st r ong abr asi ves i n aut omot i ve pai nt s.
These abr asi ves wi l l wear out needl e val ves i n shor t
or der . As a gener al r ul e, t he l i f e expect ancy of a
needl e val ve i s about 25 bi cycl e f r ame pai nt i ng j obs.
Wear on t he needl e val ve can be i dent i f i ed as a shi ny
r i ng appear i ng ar ound t he t aper at t he f r ont end of t he
needl e val ve. Fi gur e 325a shows a new needl e val ve and
f i gur e 325b shows a wor n needl e val ve. Pul l i ng t he val ve
out and put t i ng i t back i n i s qui t e si mpl e. J ust
unscr ew t he f l ui d cont r ol ( f i g. 321) al l t he way and
t he needl e val ve can be pul l ed st r ai ght back and out .
Rever se t he pr ocedur e t o r epl ace t he val ve. Somet i mes a
di f f i cul t y ar i ses when t he t hr ee- pi ece needl e val ve i s
compl et el y di sassembl ed or a di f f er ent model needl e
val ve must be pur chased. I n ei t her of t hese cases, t he
t wo l ocknut s must be r ei nst al l ed on t he needl e at t he
r i ght adj ust ment . I t i s i mpor t ant t hat t he ai r
passageway opens up bef or e t he pai nt passageway opens.
Thi s can be done by scr ewi ng t he l ocknut s backwar d or
f or war d on t he back end of t he needl e ( f i g. 324) . The
pr oper set t i ng wi l l have t he t r i gger hi t t i ng t he st ud
t hat opens t he ai r f l ow ( whi t e ar r ow i n f i g. 326) , about
1/ 32" bef or e i t opens up t he f l ui d f l ow ( bl ack ar r ow i n
f i g. 326) .
3. Af t er pai nt i ng 12 t o 15 f r ameset s, t he gun and cup
shoul d be compl et el y br oken down and soaked f or sever al
hour s i n pai nt r emover . Di t zl er Ai r cr af t Remover wor ks
wel l . Al l or i f i ces and passageways shoul d be cl eaned out
wi t h a f i ne br ush. ( Pet st or es sel l f i sh aquar i um
br ushes t hat ar e l i ke mi ni at ur e bot t l e br ushes. ) Never
cl ean or i f i ces or passageways wi t h met al obj ect s!
Smal l er hol es t hat ar e cl ogged may be cl eaned wi t h an
i ndi vi dual br i st l e of a bot t l e br ush. Whi l e r eassembl i ng
t he gun, be sur e al l pai nt r emover i s compl et el y
r emoved. When t he gun i s f ul l y assembl ed, f l ush i t
t hor oughl y wi t h sol vent . Pai nt r emover l ef t i n t he gun
coul d r ui n t he next pai nt j ob! Don' t f or get t o shoot
pai nt t hr ough t he gun f or 15 or 20 seconds at t he
begi nni ng of t he next pai nt i ng sessi on. Sol vent l ef t i n
t he gun coul d al so r ui n t he next pai nt j ob.
4. The set of t i ny r ubber gasket s and t he t ef l on seal
shoul d be r epl aced on t he Bi nks #115 af t er pai nt i ng
about 50 f r ameset s. Thi s i s qui t e si mpl e and
i nexpensi ve t o do and coul d be done dur i ng about ever y
t hi r d br eakdown of t he gun.
By f ol l owi ng t hese mai nt enance st eps, a gun wi l l gi ve
many year s of t op- not ch ser vi ce. The benef i t s ar e obvi ous
i mmedi at el y. The r esul t - - i mpr oved pai nt f i ni shes.
THE COMPRESSOR
The compr essor i s a val uabl e pi ece of equi pment i n any shop.
I t has appl i cat i ons i n machi ne, wel di ng, woodwor ki ng, r epai r , and
ot her t ypes of shops. I n sel ect i ng a compr essor f or a pai nt shop
t her e ar e t wo consi der at i ons t o be made: 1) Ther e shoul d be a way
of set t i ng t he l i ne pr essur e f or di f f er ent pai nt pr oduct s; i f a
di aphr agmf or adj ust i ng pr essur e i s not avai l abl e, an i n- l i ne ki t
can be pur chased. , 2) The compr essor shoul d be abl e t o del i ver
about 5 cubi c f eet of ai r per mi nut e at 60 psi . Her e ar e a f ew
hi nt s and suggest i ons f or compr essor set - up and mai nt enance:
1. I nst al l a wat er ext r act or i n t he l i ne r unni ng t o t he pai nt
gun. Thi s wi l l ensur e t hat no wat er vapor get s i nt o t he
pai nt spr ay mi st .
2. I t i s not a good i dea t o r un ai r t ool s of f t he same l i ne as
t he pai nt gun. Oi l used f or l ubr i cat i ng ai r t ool s can back
up i n t he l i ne and event ual l y go t hr ough t he pai nt gun. Some
wat er ext r act or s ext r act oi l as wel l .
3. The t ank of t he compr essor shoul d be bl ed on a r egul ar basi s.
Humi di t y i n t he ai r wi l l bui l d up i nsi de t he t ank t i l l i t
becomes wat er agai n. A compr essor kept i n a basement i n a
humi d cl i mat e can bui l d up over a quar t of wat er per mont h!
11- 12
4. I f t he compr essor i s t he pi st on t ype, check t he oi l l evel i n
t he cr ankcase at l east f our t i mes a year .
5. Check t he vol t age bei ng del i ver ed t o t he mot or . A l ow power
suppl y coul d bur n out t he mot or .
6. I f usi ng ext ensi on cor ds, use heavy dut y ones t hat can
handl e t he power suppl y. Li ght dut y ext ensi on cor ds can
r educe t he power suppl y and can event ual l y damage t he mot or .
7. Check t he bel t f r equent l y t o make sur e i t i s not sl i ppi ng on
t he pul l eys.
8. Check t he pul l ey set scr ews t o make sur e t he pul l eys ar e
not sl i ppi ng on t he shaf t s.
9. I f t her e i s an ai r f i l t er f or i ncomi ng ai r , see t hat i t i s
kept cl ean. See owner ' s manual f or pr oper cl eani ng
pr ocedur es.
THE BREATHI NG SYSTEM
I t can not be st r essed enough t hat pai nt i ng wi t h aut omot i ve
pai nt s i s ext r emel y hazar dous t o a per son' s heal t h. The act i ve
i ngr edi ent s i n pol yur et hane enamel s ar e pol y- i so- cyanat es. Some
of t he chemi cal di sast er s i n t hi s decade have been wi t h t he
cl osel y- r el at ed met hyl - i so- cyanat es. These cyani de- based
chemi cal s ar e ki l l er s, as has been demonst r at ed i n t he news
l at el y. I n ot her wor ds, pol yur et hane enamel s can be ki l l er s under
t he wr ong ci r cumst ances. The l ung, ner ve, ki dney, and l i ver
damage caused by r epeat ed exposur e t o t hese pr oduct s i s cumul at i ve
and per manent ! I f t he cor r ect pr ecaut i ons ar e t aken whi l e
pai nt i ng, t he r i sk i s subst ant i al l y l ower ed. I f t he maxi mum
pr ecaut i ons possi bl e ar e t aken, t her e i s l i t t l e or no heal t h r i sk.
Pr oper vent i l at i on has al r eady been di scussed, but t hat i s onl y
hal f of i t . The ot her hal f i s a pr oper br eat hi ng syst em.
Pai nt i ng wi t h a boot h i s not enough. Not onl y do t he vapor s have
t o be exaust ed away, t he pai nt er has t o be get t i ng a good suppl y
of f r esh ai r t o br eat h.
Ther e ar e f our t ypes of br eat hi ng syst ems di scussed her e: 1)
t he di sposabl e f i ber mask, 2) t he f ace mask wi t h char coal f i l t er s
i n t he f r ont of t he cheeks, 3) t he f ace mask wi t h t he back- mount ed
char coal f i l t er , and 4) f ul l cover age f ace masks wi t h an
i ndependent ai r suppl y.
Bef or e begi nni ng a di scussi on of t hese r espi r at or s, t he
subj ect of f aci al hai r shoul d be ment i oned. A pai nt er wi t h a
bear d i s at a gr eat er heal t h r i sk t han one who i s cl ean- shaven. A
bear d br eaks t he ai r seal ar ound t he si des of t he mask. When t hi s
seal i s br oken, pai nt f umes can easi l y l eak i n t he si des of t he
mask. Thi s makes t he r espi r at or a usel ess pi ece of equi pment . A
must ache i s usual l y no pr obl emsi nce t he mask cr eat es an ai r seal
over t he br i dge of t he nose and has no cont act wi t h t he upper l i p.
Ther e i s onl y one mask sui t abl e f or a pai nt er who i nsi st s on
havi ng a bear d. Thi s i s a f ul l cover age mask wi t h an i ndependent
ai r suppl y and wi t h an ai r seal ar ound t he neck.
11- 13
THE DI SPOSABLE FIBER MASK
Sever al compani es manuf act ur e a di sposabl e mask ( f i g.
327) . These usual l y come i n a box of 10 f or l ess t han $10. 00.
These masks ar e absol ut el y not sui t abl e f or pai nt i ng wi t h
aut omot i ve pai nt s! They shoul d onl y be used f or t he
f ol l owi ng r easons:
1. Sandi ng oper at i ons wi t h a l ot of ai r bor n dust
2. Pr ot ect i on when br eat hi ng col d ai r
A di sposabl e mask r emoves a f ai r l y l ar ge per cent age of
par t i cul at es but i t does not r emove chemi cal vapor s
associ at ed wi t h pai nt i ng.
THE FACE MASK WITH CHARCOAL FILTERS IN FRONT OF THE CHEEKS
The next t ype of r espi r at or i s t he one wi t h f i l t er s i n
f r ont of t he f ace ( f i gs. 328 & 329) . Thi s mask r emoves some
chemi cal vapor s, as wel l as a hi gh per cent age of
par t i cul at es. The act i vat ed char coal i n t he f i l t er s i s what
hel ps t hi s uni t r emove some of t he chemi cal vapor s. However ,
t hi s mask i s not sui t abl e f or aut omot i ve pai nt i ng ei t her .
The mai n r eason i s t hat i t t akes i t s ai r suppl y f r omt he ar ea
di r ect l y i n f r ont of t he f ace. The ar ea i n f r ont of t he
pai nt er ' s f ace has a ver y hi gh concent r at i on of pai nt f umes;
t hi s i s t r ue no mat t er how good t he vent i l at i on syst emi s.
Dr awi ng an ai r suppl y f r omi n f r ont of t he pai nt er ' s f ace i s
ext r emel y hazar dous. Thi s t ype of mask shoul d onl y be used
f or t he f ol l owi ng oper at i ons:
1. Sandi ng oper at i ons wi t h a l ot of ai r bor n dust
2. Pr ot ect i on whi l e br eat hi ng col d ai r
3. Wel di ng and br azi ng oper at i ons wher e cadmi umf umes or
a l ot of soot i s bei ng pr oduced.
Agai n, t hi s mask i s not adequat e f or aut omot i ve pai nt i ng.
11- 14
FACE MASK WI TH THE BACK MOUNTED CHARCOAL FI LTER
A f ew compani es manuf act ur e a r espi r at or t hat has a hose
goi ng t o a char coal f i l t er mount ed on t he pai nt er ' s back
( f i g. 330 & 331) . Thi s t ype of uni t i s t he mi ni mum
r equi r ement f or saf el y pai nt i ng wi t h aut omot i ve pai nt s. The
ai r suppl y behi nd t he pai nt er i s r el at i vel y f r ee f r om
cont ami nant s when wor ki ng i n f r ont of a wel l desi gned boot h.
Si nce t hi s r espi r at or has a hose bet ween t he mask and t he
char coal pack, i t has an added advant age. I f t he uni t comes
wi t h a mask t hat onl y cover s t he nose and mout h, a f ul l f ace
mask can be pur chased and easi l y scr ewed i nt o pl ace. Ful l
f ace cover age wi l l pr ot ect t he eyes whi ch act as a f ai r l y
di r ect pat hway t o t he i nsi de of t he body.
11- 15
FULL COVERAGE FACE MASKS WI TH I NDEPENDENT AI R SUPPLY
Sever al compani es manuf act ur e t ot al br eat hi ng syst ems f or
pai nt i ng wi t h aut omot i ve pai nt s. These have a f ace mask
( usual l y f ul l cover age) wi t h a hose t hat at t aches t o a wast e
bel t . A l ong hose connect s t he mask at t he wast e bel t t o a
di aphr agmcompr essor whi ch i s a di st ance away or i n anot her
r oom. Thi s syst emdr aws an ai r suppl y f r oman uncont ami nat ed
ar ea and br i ngs i t t o t he pai nt er . Thi s t ype of syst em
pr ovi des maxi mumpr ot ect i on, and br i ngs heal t h r i sks t o an
absol ut e mi mi mum. When t hi s syst emi s set up pr oper l y, i t
can be used t o handl e a mul t i t ude of danger ous subst ances.
Fi gur e 332 shows t he Bi nks br eat hi ng syst em. A par t i al
cover age mask can be seen i n f i gur e 334 and a f ul l cover age
mask by MSA i s i n f i gur e 333. Her e ar e some suggest i ons f or
set t i ng up an i ndependent ai r suppl y syst em:
1. Or der t he uni t wi t h a f ul l cover age f ace mask.
2. Use onl y di aphr agmor oi l l ess compr essor s! A pi st on
t ype compr essor wi l l del i ver oi l f umes f r omt he
cr ankcase t o t he f ace mask. Thi s poses an even mor e
sever e heal t h r i sk t han t he pai nt woul d. An over heat ed
shop compr essor wi l l act ual l y pr oduce car bon monoxi de
f umes! The r esul t of usi ng t he r egul ar shop compr essor
f or a br eat hi ng syst emcoul d act ual l y be f at al . I n
whi ch case t he pai nt er need not wor r y about l ong t er m
ef f ect s.
3. Do not use a hol di ng t ank of any sor t f or t he
compr essor ! St or i ng ai r f or br eat hi ng i n a t ank shoul d
onl y be done by hospi t al s, emer gency cr ews and SCUBA
shops. To be done pr oper l y, t he ai r must be f i l t er ed
sever al t i mes and have t he cor r ect moi st ur e cont ent .
Thi s cannot be ef f ect i vel y done i n a pai nt shop. The
net r esul t woul d be br eat hi ng a "f oul " ai r suppl y.
4. I f t her e ar e no si mpl e dust f i l t er s on t he compr essor ' s
i nt ake por t , f ashi on some si mpl e ones out of cl ean f oam
r ubber .
5. Set up t he syst emso t hat t he compr essor wi l l del i ver an
ai r suppl y f r omanot her r oomt hat can be seal ed ( by a
door ) f r omt he wor k ar ea. An added pr ecaut i on woul d be
t o r un a hose f r omt he compr essor ' s i nt ake t o an out door
ai r suppl y. Do not set t he di aphr agmcompr essor i n a
"dead ai r " ar ea. Good vent i l at i on and ai r ci r cul at i on
i n t he r oomi s ver y i mpor t ant .
11- 16
PREPARATI ON FOR PAI NTI NG
A pai nt j ob can onl y be as good as t he i ni t i al pr epar at i on of
t he under l yi ng met al . I n pr epar i ng t he f r ame f or pai nt i ng, t he
sur f ace must be t ot al l y cl eaned of dust , oi l , r ust and any ol d
pai nt t hat woul d be pr esent when r epai nt i ng an ol der f r ame.
Fai l ur e t o r emove any of t hese subst ances can r esul t i n a poor
pai nt j ob.
REMOVI NG OLD PAI NT
Removi ng ol d pai nt can be done i n a var i et y of ways: 1)
wi t h a chemi cal st r i pper , 2) sandbl ast i ng and 3) wet sandi ng.
CHEMI CAL STRI PPI NG
One met hod of chemi cal l y r emovi ng pai nt i s done by
br ushi ng on a commer ci al l y pr epar ed pai nt st r i ppi ng sol ut i on
( f i g. 335) . As t he pai nt st ar t s t o sof t en and wr i nkl e, i t can
be gent l y scr aped of f . Thi s pr ocess may have t o be r epeat ed
sever al t i mes bef or e t he pai nt i s f ul l y r emoved. I n t he case
of mor e st ubbor n pat ches of pai nt or har d- t o- get - at pl aces, a
wi r e wheel wor ks wel l .
Pai nt st r i pper s have some power f ul chemi cal s i n t hem.
For t hi s r eason, adequat e vent i l at i on i s an absol ut e must ,
and r ubber gl oves ar e al so r equi r ed. Do not use l at ex gl oves,
as t he pai nt r emover wi l l di sol ve t hemaf t er a per i od of
t i me. Saf et y gl asses shoul d al so be wor n, especi al l y when
wor ki ng on t he wi r e wheel . The wi r e wheel wi l l t hr ow up
pi eces of wi r e occasi onal l y, as wel l as smal l gl obs of pai nt
r emover . I f ei t her of t hese get s i nt o t he eyes, i t i s ver y
pai nf ul and coul d even r esul t i n a vi si t t o t he doct or .
11- 17
I f t he sol ut i on i s chemi cal l y compat i bl e wi t h t he
exi st i ng pai nt j ob, t he ol d pai nt wi l l i mmedi at el y st ar t t o
wr i nkl e and separ at e f r omt he f r ame. I f t he st r i pper i s not
t he cor r ect mat ch f or t he ol d pai nt , i t wi l l be a r eal chor e
t o r emove i t . For t hi s r eason, i t i s i mpor t ant t o buy t he
cor r ect pai nt st r i pper . Do not buy a pai nt st r i pper f r omt he
l ocal har dwar e st or e. Most of t hose st r i pper s ar e f or
var ni sh, l at ex pai nt and oi l base enamel s. Go t o an
aut omot i ve suppl y st or e and buy some aut omot i ve pai nt
st r i pper or ai r cr af t pai nt st r i pper . ( The aut hor ' s f avor i t e
br and i s Ai r cr af t Remover by Di t zl er ( f i g. 335) . I t i s qui t e
power f ul and i s wat er sol ubl e ( f i g. 336) , so cl ean- up i s
easy. )
Anot her met hod of chemi cal l y st r i ppi ng pai nt i s t o set up
a di p t ank of met hyl - chl or i de. Met hyl - chl or i de i s t he act i ve
i ngr edi ent i n many br ands of pai nt st r i pper s. When pai nt
st r i pper s ar e pr epar ed, t he met hyl - chl or i de must be combi ned
wi t h a car r i er t hat gi ves t he f i nal pr oduct a j el l y- l i ke
consi st ency. Thi s al l ows t he st r i pper t o be appl i ed wi t hout
i mmedi at el y f al l i ng of f t he i t embei ng st r i pped.
Unf or t unat el y, t he j el l y- l i ke car r i er di mi ni shes t he pot ency
of t he st r i pper . I f pur e met hyl - chl or i de i s put i nt o a st r i p
t ank, i t i s much mor e power f ul t han any commer ci al l y pr epar ed
sol ut i on. I t i s al so f ar mor e hazar dous t han any
commer ci al l y made pr oduct ! Wi t h a di p t ank of t hi s sor t , a
f r ame can be di pped and t he pai nt shoul d f al l of f i n onl y a
f ew mi nut es. One maj or dr awback of t hi s met hod i s t he
expense. The sol ut i on must be r epl aced when i t becomes
hi ghl y cont ami nat ed wi t h sl uf f ed- of f pai nt . Met hyl - chl or i de
i n 30- gal l on dr ums i s qui t e expensi ve. Her e ar e some saf et y
hi nt s f or set t i ng up a di p t ank:
1. Use onl y heavy- gage st ai nl ess or soapst one i n
const r uct i ng t he t ank. Ol d chemi st r y l ab si nks ar e
i deal .
11- 18
Bel ow i s a di agr amof t he cor r ect way t o set up a di p t ank.
Fireproof cover- must fall to closed position from its own weight
36"X 48
"
X 1 0
"
soapstone or stainless tank
2. The di p t ank must have a l i d wi t h over l appi ng si des.
3. Set up t he t ank i n a wel l vent i l at ed ar ea.
4. Fl oat 5cmof wat er on t op of t he met hyl - chl or i de. Thi s
cut s evapor at i on mar kedl y. I t i s t he evapor at i on t hat
i s t he r eal hazar d.
5. Have a way of l ocki ng t he t ank and keep i t l ocked up at
al l t i mes when not i n use!
ill.1 32: Dip tank
SANDBLASTI NG
Anot her way of r emovi ng pai nt i s by sandbl ast i ng. Thi s
i s an accept abl e met hod f or r emovi ng pai nt f r omheavi er and
cheaper f r ames. Sandbl ast i ng i s qui t e har sh on t he sur f ace
of t he f r ame. I n t he case of l i ght wei ght t ubi ng, i t i s
possi bl e act ual l y t o bl ow a hol e t hr ough t he t ubi ng wal l i f
t he wor ker i s not car ef ul . Sandbl ast i ng can al so r emove
br azi ng mat er i al f r omj oi nt s l eavi ng unsi ght l y gaps i n some
i nst ances. Sandbl ast i ng does have one r edeemi ng gr ace: I t
can act ual l y put st r engt h back i nt o an over heat ed br ass
br azed f r ame. ( I n ways, sandbl ast i ng i s ver y si mi l ar t o shot
peeni ng. Shot peeni ng i s done t o met al obj ect s t o r el i eve
st r esses bui l t up dur i ng hi gh t emper at ur e pr ocesses. ) I f t he
deci si on i s made t o sandbl ast f r ames, choose a r el i abl e
f i r mt o do i t and make sur e t hey ar e awar e of t he pr obl ems of
wor ki ng wi t h bi cycl es.
WETSANDI NG
Wet sandi ng shoul d not be done wi t h t he i nt ent i on of
r emovi ng al l of t he pai nt . I t shoul d be done t o a f r ame t hat
i s r ecei vi ng t ouch- up wor k. I n t he case of a f r ame t hat has
been di nged up wi t h a f ew chi ps and scr at ches, t hese
11- 19
i mper f ect i ons can be "f eat her ed out " wi t h a pi ece of
Wet or dr y sandpaper and wat er . ( Wet or dr y i s a 3M br and name
t hat desi gnat es a t ype of sandpaper t hat can be used wet or
dr y. ) When used wi t h wat er , Wet or dr y paper wi l l not cl og up
as easi l y. Thi s al l ows t he paper t o be used much l onger
bef or e di scar di ng i t . To f eat her out ni cks and scr at ches i n
a pai nt j ob, use a 320 gr i t paper . Af t er al l of t he
wet sandi ng i s done, t he f r ame may be shot wi t h a new coat of
pai nt r i ght over t he ol d coat . Bel ow, f i gur e 337
shows a poor j ob of wet sandi ng wher e sanded edges ar e t oo
abr upt . Fi gur e 338 shows a good j ob of f eat her i ng.
NOTE: I t i s t he per sonal pr ef er ence of t he aut hor not t o
wet sand any f r ame ot her t han one of hi s own. Wet sandi ng and
r epai nt i ng a st r ange f r ame can be a r eal headache. I f an
i nf er i or pai nt j ob was done by someone el se, t he wet sanded-
r epai nt ed pai nt j ob wi l l be onl y as good as t he or i gi nal
pai nt j ob. I f pr obl ems devel op i n t he f ut ur e, t he cust omer
wi l l expect a f r ee r epai nt by t he l ast per son t o pai nt t he
f r ame.
METALPREP
Af t er t he f r ame has been compl et ed ( st ep VI - 42 on page
3- 51) or when t he pai nt has been ent i r el y st r i pped f r oman
ol der f r ame, a phosphor i c aci d scr ub- down must be done.
Doi ng t hi s wi l l cl ean and "et ch" t he sur f ace of t he met al t o
be pai nt ed ( et chi ng r ef er s t o t he act i on of t he aci d on t he
met al ) . By appl yi ng phosphor i c aci d t o t he sur f ace of t he
met al , r ust i ng can be gr eat l y i nhi bi t ed or even ar r est ed.
Thi s wi l l al l ow t he pai nt t o be spr ayed ont o a sur f ace t hat
has no r ust on i t . Her e some saf et y hi nt s f or doi ng a
phosphor i c aci d scr ub down:
11- 20
1. Wear r ubber gl oves when handl i ng phosphor i c aci d. I f
t he aci d comes i n cont act wi t h open sor es, scabs, or
mucous membr anes i t wi l l eat away body t i ssues f or days
unt i l t he body can neut r al i ze t he aci d.
2. Wear a r espi r at or mask. A si mpl e one wi t h char coal
f i l t er s wi l l do.
3. Do t he scr ub down out si de. I ndoor s, t he aci d f umes wi l l
r ui n l at ex pai nt j obs on i nt er i or wal l s.
4. Wear l ong sl eeves and l ong pant s i n case of spl ashi ng.
5. Saf et y gl asses woul d not be a bad i dea.
Fol l owi ng ar e t he act ual st eps t o use i n per f or mi ng t he
phosphor i c aci d scr ub- down:
1. Obt ai n t he f ol l owi ng: DuPont 5717S met al pr ep
( phosphor i c aci d) , A Br i l l o or 3M gr een scour i ng pad
wi t h no soap ( ot her br ands wi l l decompose i n t he aci d) ,
a smal l hypoder mi c syr i nge wi t h t he needl e r emoved, a
di sposabl e pl ast i c bowl wi t h about a pi nt capaci t y, and
a t er r y cl ot h r ag.
2. Fi l l t he bowl about hal f f ul l of aci d. The di r ect i ons
say t o di l ut e t he aci d, but f ul l st r engt h gi ves qui cker
r esul t s.
3. Wi t h t he gr een pad, scr ub t he ent i r e sur f ace of t he
f r ame and f or k wi t h t he aci d. Don' t be af r ai d t o scr ub
har d. Do not scr ub chr omed ar eas.
4. Fi l l t he syr i nge wi t h aci d and shoot i t i nsi de of al l of
t he t ubes. Remember , i t was sai d l ar ge ai r expansi on
hol es wer e i mpor t ant ( f i g. 66) . I t was al so r ecommended
t o dr i l l t wo ai r expansi on hol es f or each t ube ( f i gs. 97
& 135) . Al l of t hese ear l i er suggest i ons wer e gi ven t o
make t he phosphor i c aci d f l ush mor e ef f ect i ve.
5. Al l ow t he f r ame and f or k t o st and f or 10 t o 15 mi nut es
so t he aci d wi l l have t i me t o et ch t he met al . Thi s wi l l
t ake l ess t i me i n war mer sur r oundi ngs.
6. Thor oughl y r i nse t he out si des and f l ush t he i nsi des of
t he t ubes wi t h col d wat er . Usi ng col d wat er wi l l al l ow
mor e t i me t o wor k bef or e t he f r ame st ar t s dr yi ng of f .
7. Towel t he f r ame and f or k dr y wi t h t he t er r y cl ot h r ag.
8. Wi t h t he ai r bl ower f r omt he compr essor , bl ow any
r emai ni ng r esi due f r omany of t he cr evi ces of t he f r ame
and f or k. Al so bl ow i nt o each ai r expansi on hol e so any
r esi due f r omi nsi de t he t ubes wi l l come out t he opposi ng
ai r expansi on hol e. ( Ti me f or saf et y gl asses)
MASKI NG AND I NSTALLI NG PAI NTI NG HANDLES
Now t hat t he met al pr ep has been f i ni shed, pai nt i ng
handl es can be i nst al l ed and maski ng can be done. Not e t he
di f f er ent pai nt i ng handl es t hat can be f ashi oned ( f i gs. 339
t hr ough 344) . These al l ow t he f r ame t o be handl ed easi l y
wi t hout t he f ear of smear i ng t he pai nt .
11- 21
11-22
Maski ng can be br oken down t wo ways: 1) necessar y and
2) cosmet i c.
Necessar y maski ng consi st s of t he f or k cr own r ace seat
( f i g. 345) , t he smal l cyl i nder of cant i l ever st uds, t he
cyl i ndr i cal por t i on of shi f t l ever st uds, t he bot t ombr acket
f aces ( unl ess a seal ed bot t ombr acket set wi l l be used) , and
t he head t ube ends whi ch ar e opt i onal ( f i g. 346) . Al l f r ames
shoul d have t hese i t ems masked t o make assembl y of t he
compl et ed bi ke easi er . By maski ng t hese i t ems, bear i ng seat s
do not have t o be r ecut and t hr eads do not have t o be cl eaned
out . Al l of t hese may be masked wi t h a hi gh gr ade of maski ng
t ape except t he bot t ombr acket f aces whi ch ar e cover ed by t he
p
ai nt i ng handl es.
Cosmet i c maski ng consi st s of maski ng chr ome and maski ng
f or a t wo t one pai nt j ob. Maski ng chr ome may be done i n t wo
ways. One way i s t o cover t he whol e ar ea wi t h a hi gh gr ade
of maski ng t ape and car f ef ul l y cut t i ng t he excess away wi t h a
r azor kni f e ( f i g. 347) . The ot her way i s t o car ef ul l y pai nt
t he ar ea t o be masked wi t h r ubber cement , whi ch can be r ubbed
of f af t er t he pai nt j ob i s f i ni shed ( f i g. 348) . ( The aut hor
has had ver y l i t t l e exper i ence wi t h t he l at t er met hod and
pr ef er s maski ng t ape. ) Some l unat i cs have suggest ed appl yi ng
gr ease t o t he chr omed ar eas and r ubbi ng i t of f af t er t he
pai nt j ob i s f i ni shed. Ther e coul d be no bet t er way t o
cr eat e t he wor st r ash of "f i sheyes" ever seen on a bi cycl e
f r ame! Al l pai nt er s shoul d be doi ng ever yt hi ng possi bl e t o
keep oi l and gr ease away f r omal l pai nt i ng equi pment and
suppl i es. Maski ng panel s i n a t wo t one j ob can be done wi t h
a combi nat i on of f r eezer or waxed paper and maski ng t ape.
The f r eezer paper can be cut t o near l y t he si ze needed and
wr apped ar ound t he t ube wi t h t he sl i ck si de t owar d t he f r ame.
Maski ng t ape can t hen be used t o f i ni sh i t of f ar ound t he
edges ( f i g. 349) . Do not use a f i br ous paper l i ke newspaper
t o mask wi t h.
11- 23
A wor d about maski ng t ape - Do not buy r ol l s of maski ng
t ape at t he di me st or e or har dwar e st or e and expect good
per f or mance f r omi t . Such t ape i s t hi cker and st i f f er and
har der t o wor k wi t h. For not much mor e money, t he r i ght t ape
can be pur chased at aut omot i ve suppl y st or es. Usi ng t he
r i ght t ype of maski ng t ape al l ows t he pai nt er t o "f or m" i t
ar ound cur ves. The t hi nner t ape wi l l al so l eave l ess of a
r i dge bet ween t he col or s. Al ways r emove maski ng t ape as soon
as possi bl e! I f l ef t f or t oo l ong a per i od of t i me, maski ng
t ape can even r ui n a chr ome f i ni sh.
DEGREASING AND USE OF TACK RAG
Af t er maski ng and i nst al l i ng of pai nt i ng handl es, t he
f r ame shoul d be degr eased and gone over wi t h a t ack r ag.
Thi s i s a si mpl e pr ocess but ver y i mpor t ant . The f r ame has
been handl ed ext ensi vel y up t o t hi s poi nt and has a var i et y
of cont ami nant s on i t s sur f ace, t he wor st of whi ch woul d be
oi l or gr ease t hat coul d have come f r ombench t ops, or even
t he pai nt er ' s hai r or per spi r at i on. To r emove t hese
subst ances, soak a paper t owel i n l acquer t hi nner and wi pe
down t he f r ame and f or k. ( Don' t f or get good vent i l at i on! )
Tr y t o use a paper t owel t hat does not l eave much l i nt .
Af t er degr easi ng, wi pe t he f r ame and f or k t hor oughl y wi t h a
t ack r ag. A t ack r ag i s a pi ece of cheese cl ot h i mpr egnat ed
wi t h a st i cky, waxy subst ance t hat wi l l r emove al l par t i cl es
of l i nt f r omt he sur f ace of t he f r ame and f or k. Tack r ags
can be pur chased f r oman aut omot i ve pai nt suppl y st or e. They
ar e r el at i vel y i nexpensi ve. Pur chase 2 or 3 br ands and see
whi ch wor ks best . ( Some br ands ar en' t ver y good. ) Donot
wor r y about l eavi ng some of t he waxy subst ance on t he met al
sur f ace - i t i s compat i bl e wi t h t he pai nt s t hat wi l l be used.
11- 24
A HEALTH WARNI NG
Her e agai n, i t i s of i mpor t ance t o war n about t he heal t h r i sks
i nvol ved i n pai nt i ng wi t h aut omot i ve pai nt s. They ar e ki l l er s!
I f t her e ar e any second t hought s about usi ng t hem, t al k t o a
t oxi col ogi st ( a medi cal doct or speci al i zi ng i n poi sonous
subst ances and t hei r ef f ect s on t he human body) . I f t her e ar e
chi l dr en ar ound t he shop, t hey ar e at a heal t h r i sk. Pr egnant
women shoul d by al l means avoi d any exposur e t o t he f umes. Men
who ar e consi der i ng f at her i ng a f ami l y i n t he near f ut ur e may be
r i ski ng bi r t h def ect s. Peopl e wi t h r espi r at or y ai l ment s such as
ast hma or emphysema can di e i n a mat t er of mi nut es due t o over
exposur e t o t hese pai nt f umes. Long- t er mcumul at i ve and per manant
damage t o t he ner vous syst em, l i ver , and l ungs can r esul t f r om
car el ess use of t hese pr oduct s.
On t he ot her si de of t he coi n, t he per f or mance of pol yur et hane
enamel s out per f or ms any ot her pai nt on t he mar ket . Many pai nt er s
woul dn' t even t hi nk of usi ng anyt hi ng ot her t han pol yur et hane
enamel s.
I f , af t er consi der i ng t he i mpl i cat i ons i nvol ved, t he
f r amebui l der deci des not t o go i nt o pai nt i ng f r ames, t her e ar e
al t er nat i ves. One al t er nat i ve i s t he "r at t l e can" met hod. Thi s
i s a bad choi ce at best . Rat t l e cans ar e manuf act ur ed f or t he
gener al publ i c and by l aw can not cont ai n any of t he chemi cal s
t hat make a hi gh qual i t y pai nt j ob so much bet t er . Fur t her mor e,
t he pr essur e used i n r at t l e cans i s so l ow t hat at omi zat i on of
pai nt par t i cl es i s poor . Last of al l , t he can i s not adj ust abl e
and t he or i f i ces ar e made of pl ast i c. Any sel f - r espect i ng bui l der
woul d not pai nt a f i ne cust omf r ame wi t h a r at t l e can. The ot her
al t er nat i ve i s pr obabl y t he best . Fi nd an exper i enced pai nt er who
i s wi l l i ng t o do t he wor k on a r egul ar basi s. Many f r amebui l der s
who ar e exper i enced pai nt er s ar e mor e t han happy t o t ake on t he
ext r a wor k. I f an aut o body pai nt er i s wi l l i ng t o do t he wor k,
t r y hi mout on a gar bage f r ame f i r st . Bi cycl e f r ames ar e t ot al l y
di f f er ent f r omcar s when i t comes t o pai nt i ng. Many aut o body
pai nt er s won' t t ouch a second f r ame af t er wr est l i ng wi t h t he f i r st
one.
PAI NT PRODUCTS
Ther e ar e sever al pai nt pr oduct s t hat can be used ef f ect i vel y
f or pai nt i ng bi cycl e f r ames. Acr yl i c l acquer , acr yl i c enamel ,
epoxy pr i mer s, and pol yur et hane enamel s ar e t he mor e popul ar ones
t hese days. Si nce t he aut hor ' s exper i ence i s most l y wi t h epoxy
pr i mer s and pol yur et hane enamel s, t hose ar e t he ones t hat wi l l be
cover ed. The t hr ee most wel l known names i n pol yur et hane enamel s
ar e Di t zl er ( Del t r on) , Sher wi n Wi l l i ams ( Sunf i r e) , and DuPont
( I mr on) . Her e agai n, t he aut hor ' s exper i ence l i es most l y wi t h
DuPont pr oduct s so t hat i s what wi l l be cover ed. Much of t he
i nf or mat i on wi l l t r ansf er over t o t he ot her br ands.
11- 25
TWO PART EPDXY PRI MER
DuPont Cor l ar i s a pr i mer t hat comes i n t wo par t s.
Number 8245 i s t he l i ght gr ay pai nt and 826S i s t he
act i vat or . Cor l ar al so comes i n a r ed oxi de col or , but t he
aut hor doesn' t r ecommend i t hi ghl y f or pai nt i ng bi cycl es due
t o t he pr obl ems i n adequat el y l i ght i ng cyl i ndr i cal obj ect s.
A new can of Cor l ar must be st i r r ed; si gni f i cant set t l i ng
occur s on t he shel f and 3 cmof sl udge on t he bot t omi s
nor mal . The act i vat or does not have t o be st i r r ed. Af t er
st i r r i ng out al l l umps, t he t wo par t s can be mi xed. Mi xi ng
shoul d be done i n a cl ean met al cont ai ner or a pl ast i c
cont ai ner f r oma chemi st r y l ab. Ther e shoul d be cal i br at i ons
vi si bl e on t he i nsi de of t he cont ai ner . The mi xi ng cup can
be cal i br at ed f or easy mi xi ng wi t h a l i ght t ap f r oma hammer
and cent er punch ( f i g. 350) . Use t wo par t s of 824S t o 1 par t
of 826S. Mi xi ng shoul d be done at r oomt emper at ur e an hour
bef or e t he pai nt wi l l be used. A good t i me t o mi x t he pai nt
i s j ust bef or e t he phosphor i c aci d met al pr ep. Thi s wi l l
al l ow an hour or so f or maski ng and degr easi ng of one or mor e
f r ames. Af t er t he pai nt has been st andi ng f or an hour or
mor e, i t i s t i me t o add r educer t o get t he r i ght vi scosi t y.
Pai nt t hat i s t oo t hi ck wi l l send spat t er out of t he f r ont of
t he gun. Pai nt t hat i s t oo t hi n wi l l r un t oo easi l y. To
achi eve t he cor r ect vi scosi t y, buy a DuPont vi scosi met er
( f i g. 351) . I t onl y cost s about $5. 00 and i s wor t h i t s wei ght
i n gol d. For pr i mi ng bi cycl e f r ames, DuPont Cor l ar shoul d
r un t hr ough t he vi scosi met er i n 20 seconds. ( Poi nt of
i nt er est : I f t oo much Cor l ar i s mi xed up, i t can be
r ef r i ger at ed f or up t o 2 weeks. I f i t i s r ef r i ger at ed, i t
can not be put i n t he same r ef r i ger at or wi t h f ood. Si nce
Cor l ar l ooks l i ke mi l k, use onl y i t s or i gi nal can t o st or e i t
i n t hi s manner . Put a hasp on t he r ef r i ger at or door and
padl ock i t ! )
351
11- 26
REDUCER
Reducer i s anot her wor d f or t hi nner . Reducer s ar e
"speci f i c. " I n ot her wor ds, t he cor r ect r educer must be used
wi t h t he pai nt t hat i s bei ng used. I f i n doubt , l ook at t he
di r ect i ons on t he back of t he pai nt can t o f i nd out whi ch
r educer i s r ecommended. I t i s not a good i dea t o mi x and
mat ch br ands of pai nt pr oduct s. Because of mi nor var i at i ons
i n f or mul as, al ways use DuPont r educer s t o add t o DuPont
pai nt pr oduct s. Cor l ar may be t hi nned or r educed wi t h #3602S
DuPont acr yl i c l acquer r educer . DuPont makes sever al acr yl i c
l acquer r educer s t hat wi l l wor k. However , #3602S i s a "f ast "
r educer t hat wi l l f l ash over f ast er t han t he ot her s. Thi s
wi l l al l ow t he col or coat t o be appl i ed sooner and wi l l al so
l essen t he pr obabi l i t y of r uns.
Pai nt s shoul d be r educed i n t he pai nt boot h wi t h al l
r espi r at i on equi pment i n pl ace and t he vent i l at i on syst em
t ur ned on. A pai r of r ubber gl oves shoul d be wor n f r omnow
unt i l t he f r ame i s f ul l y pai nt ed. Lat ex ki t chen gl oves ar e
l ess cumber some and wi l l not br eak down i n pai nt i ng
chemi cal s.
Cl ean- up of pai nt equi pment af t er wor ki ng wi t h Cor l ar can
be done wi t h acr yl i c l acquer t hi nner . See gun mai nt enance.
LI NT CHECK
Thi s i s al so a good t i me f or t he pai nt er t o check out t he
cl ot hi ng he has on. Fl annel , wool , or any ot her f uzzy
mat er i al shoul d not be wor n whi l e pai nt i ng. The ai r bor ne
l i nt par t i cl es wi l l be dr awn t hr ough t he boot h due t o t he ai r
f l ow. These l i nt par t i cl es can l and on t he f r ame and cause
unsi ght l y bl emi shes. Anot her good way t o cut down t he
pr obl emof ai r bor n l i nt par t i cl es i s t o spr ay a l i ght mi st of
wat er i n t he ai r wi t h a pl ant mi st er . The wat er dr opl et s
wi l l cl i ng t o dust and l i nt par t i cl es and dr op t o t he f l oor .
POLYURETHANE ENAMEL
DuPont I mr on i s al so a t wo par t pai nt . However , don' t
conf use i t wi t h an epoxy pai nt , l i ke Cor l ar , whi ch i s al so a
t wo- par t pai nt . I mr on i s a pol yur et hane enamel . I mr on does
not si t on a shel f and set t l e f or mont hs at a t i me l i ke
pr emi xed pai nt s. The col or r equest ed i s mi xed when i t i s
or der ed. Thi s does not mean t hat st i r r i ng or shaki ng i s not
necessar y. Af t er t he I mr on i s mi xed and t aken back t o t he
pai nt shop, pi gment s and par t i cul at es i n t he pai nt st ar t t o
set t l e and go t o t he bot t omal most i mmedi at el y. I mr on must
be shaken vi gor ousl y wi t hi n one or t wo mi nut es of pour i ng i t
i nt o t he gun. I f t he I mr on i s al l owed t o si t f or any l engt h
11- 27
of t i me wi t hout bei ng shaken, a sl i ght l y di f f er ent col or wi l l
r esul t . Af t er t hat , t he or i gi nal col or f r omt hat par t i cul ar
can wi l l not be possi bl e agai n due t o an upset i n r at i os of
t he pai nt mi x.
I mr on can be r educed wi t h DuPont #8485S but , r educi ng
I mr on f or bi cycl e f r ame pai nt i ng i s not hi ghl y r ecommended.
Si nce t her e i s a pr obl emwi t h r uns occur r i ng on bi ke f r ames
al r eady, r educi ng woul d onl y make t he pr obl emwor se.
I mr on i s mi xed 3 par t s pai nt t o 1 par t act i vat or ( DuPont
#192S - I f I mr on act i vat or i s not avai l abl e, DuPont Cent ar i
act i vat or i s t he same t hi ng. ) The easi est way t o mi x t he t wo
par t pai nt i s t o car ef ul l y make f our punch mar ks up t he si de
of t he cup ( f i g. 352) . The mar ks can t hen be used t o measur e
t he pai nt . Fi r st , f i l l t he cup t o t he f i r st mar k wi t h t he
act i vat or ( f i g. 353) . ( I f t he act i vat or i s put i n f i r st , t he
mi xed pai nt wi l l not have t o be shaken as much. ) Then, pour
t he I mr on pai nt i n t o t he f our t h mar k ( f i g. 354) . The gun
shoul d now be put i n pl ace i n t he f ol l owi ng manner . Bef or e
t he ver t i cal t ube f r omt he gun t ouches t he f r eshl y act i vat ed
pai nt , depr ess t he t r i gger . Whi l e ai r i s r ushi ng t hr ough t he
gun, submer ge t he t ube. Cont i nue t o spr ay f r esh pai nt
t hr ough t he gun f or about 15 seconds. By doi ng t hi s, any
l acquer t hi nner f r omt he l ast f l ush wi l l have been expel l ed
bef or e i t has a chance t o mi x wi t h t he I mr on. Thi s i s
i mpor t ant t o do. That i ni t i al shot of l acquer t hi nner can
wr i nkl e t he back si de of a f or k bl ade or one si de of a chai n
st ay. Now, f ast en t he cup i n pl ace, pi ck up t he gun, and
gent l y swi sh i t i n a ci r cul ar mot i on t o f ur t her mi x up t he
act i vat ed I mr on. Don' t shake t he gun or pai nt wi l l come out
t he bl eeder hol e of t he cup. The I mr on i s now r eady t o
shoot .
Cl ean- up of DuPont I mr on can be done wi t h acr yl i c l acquer
r educer . See Gun Mai nt enance.
11- 28
ACCELERATOR
To hast en dr yi ng t i me, DuPont #189S pol yur et hane
accel er at or can be added. 189S shoul d be added t o an 8 oz.
cup wi t h an eyedr opper a f ew dr ops at a t i me. Addi ng
accel er at or wi l l al l ow maski ng t o be done sooner . I t may
al so be a good t hi ng t o do wi t h some of t he l i ght gr eens or
l i ght bl ues whi ch t end t o r un mor e easi l y. Occasi onal l y, t he
ver y dar k col or s wi l l l eave unsi ght l y hi ghl i ght s ar ound shar p
edges. Accel er at or may hel p sof t en t hose hi ghl i ght s. The
mai n dr awback of usi ng accel er at or i s t hat or ange peel occur s
much mor e r eadi l y. Rat i os f or 1895 ar e gi ven on t he si de of
t he bot t l e. However , f or bi cycl e f r ames, a l i t t l e
exper i ment at i on may be r equi r ed.
CLEAR COATS
Cl ear coat s may be appl i ed at any t i me - even mont hs
af t er t he col or coat . Cl ear coat s ( DuPont 500S) ar e mi xed
and appl i ed exact l y t he same way as DuPont col or coat s. Her e
ar e some suggest i ons f or appl yi ng cl ear coat s:
1. I f appl yi ng a cl ear coat i mmedi at el y af t er t he col or
coat has been appl i ed, no speci al pr epar at i on needs t o
be done. J ust shoot t he cl ear r i ght over t he t op of t he
col or . Thi s mi ght be done t o smoot h out ai r br ush wor k
or col or bl endi ng wor k.
2. I f appl yi ng a cl ear coat wi t hi n 72 hour s of nor mal ai r
dr yi ng, no speci al pr epar at i on needs t o be done. Shoot
t he cl ear r i ght over t he col or coat . Thi s woul d be done
i n t he case of pai nt i ng a t wo- t one wher e t he panel col or
i s pai nt ed on Day 1, t he base col or i s pai nt ed on Day 2,
and t he cl ear coat i s pai nt ed on Day 3.
3. Af t er l onger per i ods of dr yi ng or f or ce dr yi ng ( baki ng) ,
t he sur f ace must be gone over l i ght l y wi t h a f i ne st eel
wool bef or e appl yi ng a cl ear coat . Thi s woul d be done
t o r ej uvenat e a dul l ed or scr at ched pai nt j ob. Af t er
usi ng t he st eel wool , r ub t he f r ame down ext ensi vel y
wi t h a t ack r ag t o r emove t he massi ve par t i cl es of st eel
wool l i nt .
4. I f decal s ar e appl i ed on t op of t he pai nt j ob bef or e t he
cl ear i s appl i ed, pr obl ems ar i se. To have l ess pr obl ems
af f i xi ng decal s, t he f r ame shoul d be baked at about 125
degr ees F f or f our t o si x hour s. Wor ki ng wi t h dr y
t r ansf er decal s can be a di sast er i f t he f r ame has onl y
ai r dr i ed over ni ght . A whol e l i ne of l et t er s coul d
peel of f t he sheet and not come of f agai n under such
ci r cumst ances .The pr ocedur e t he aut hor has chosen i s t o
pai nt , bake, af f i x decal s, cl ear coat , and bake agai n.
Thi s does not al l ow t he cl ear coat t o adher e as wel l t o
t he col or coat , but t he pr ocess wor ks wel l . Anot her
pr ocedur e woul d be t o pai nt , bake, st eel wool , af f i x
decal s, cl ear coat , and bake agai n.
11- 29
FORCE DRYI NG OR BAKI NG
To speed up t he pr ocess, pai nt j obs can be f or ce dr i ed.
Some pai nt s, such as baki ng enamel s, wi l l never dr y unl ess
t hey ar e baked at 350 degr ees f or sever al hour s. Thi s i s not
t he case wi t h acr yl i c l acquer s, acr yl i c enamel s, and
pol yur et hane enamel s. They wi l l f ul l y dr y and har den ( cur e)
at r oomt emper at ur e i n about 30 days. Thi s i s wher e a
pr obl emar i ses. These pai nt j obs ar e f r agi l e and hi ghl y
suscept i bl e t o chi ps and scr at ches dur i ng t hi s dr yi ng t i me.
I t i s r i sky busi ness t o t ur n over an uncur ed pai nt j ob t o a
novi ce bi ke mechani c. Fr ame cl i ps or a bi cycl e r epai r st and
cl amp can r ui n a new pai nt j ob. * Thi s i s wher e f or ce dr yi ng
comes i n handy. A new pai nt j ob can be baked over ni ght at
about 125 degr ees F. Thi s i s about equi val ent t o t wo weeks of
ai r dr yi ng. An easy and i nexpensi ve way t o do f or ce dr yi ng i s
t o cl ose up t he pai nt boot h wi t h heat i ng l amps i nsi de i t .
Cont r ar y t o popul ar bel i ef , baki ng does not make a pai nt
j ob any st r onger t han nor mal ai r dr yi ng. I t onl y speeds
t hi ngs up.
* NOTE: Never cl amp a r epai r st and di r ect l y ont o
any hi gh qual i t y pai nt j ob whet her i t i s cur ed or not .
I f possi bl e, al ways cl amp ont o t he seat post . I f i t i s
t oo di f f i cul t t o cl amp ont o t he seat post , put some
f r eezer paper , waxed paper or 10 mi l pol y i n t he j aws of
t he cl amp each t i me a f r ame i s put i n t he st and.
DECALS
Ther e ar e t wo maj or t ypes of decal s; 1) decal s t hat ar e
cover ed wi t h a cl ear coat and 2) decal s t hat go on t op of t he
pai nt j ob.
1. Dr y t r ansf er s whi ch ar e af f i xed by r ubbi ng t hemont o t he
sur f ace ( f i g. 358) , wat er t r ansf er s whi ch ar e af f i xed by
soaki ng t hemi n wat er and sl i di ng t hemof f ont o t he
sur f ace ( f i g. 357) , and al cohol t r ansf er s ar e exampl es
of decal s t hat can. be cover ed wi t h a cl ear coat .
Appl yi ng t hese decal s t akes a l ot of pr act i ce. The
bi ggest pr obl emwi t h t he wat er and al cohol t r ansf er s i s
i n bei ng abl e t o handl e t hemdel i cat el y enough. Wat er
and al cohol t r ansf er s shoul d be al l owed t o dr y f or 8
hour s bef or e appl yi ng a cl ear coat .
2. Myl ar decal s and f oi l decal s ar e exampl es of decal s t hat
go over t he t op of t he pai nt j ob ( f i gs. 355 & 356) . Do
not t r y t o put a cl ear coat over t hemas i t wi l l not
l ook good at al l . The decal s ar e t oo t hi ck and t oo
smoot h t o cl ear coat adequat el y. Appl i cat i on i s so easy
a f i ve year ol d can do i t . J ust peel t he backi ng and
put i n pl ace.
11- 30
I n t he f our pi ct ur es above can be seen t he di f f er ent ways i n
whi ch decal s can be appl i ed. They each have t hei r advant ages and
di sadvant ages. The most ver sat i l e i s pr obabl y t he dr y t r ansf er
met hod, whi ch can be done i n over 100 t ype st yl es. However i t i s
t i me consumi ng. Wat er sl i de decal s ar e by f ar t he most
at t r act i ve, but t hey ar e t he most expensi ve. Foi l and Myl ar
decal s ar e r el at i vel y i nexpensi ve and can be used f or ot her
appl i cat i ons as wel l but , cheapen t he l ook of a cust omf r ame.
11- 31
PLATI NG
Ther e shoul d be some ment i on of t he pl at i ng of bi cycl e
f r ames. Bi cycl e f r ames can be pl at ed wi t h a var i et y of
met al s such as chr ome, br ass, si l ver , gol d, pl at i num,
ni ckel , and many ot her s. The pr esence of t he met al appl i ed
t o t he sur f ace of t he bi cycl e f r ame has no det r i ment al ef f ect
on t he st r engt h of t he st eel . However , cer t ai n aci d bat hs
ar e r equi r ed i n t he pl at i ng pr ocess. Dur i ng t hi s pr el i mi nar y
"pi ckl i ng" pr ocess t he st eel t akes on avai l abl e hydr ogen
at oms f r omt he aci d bat hs. Thi s causes what i s cal l ed
"hydr ogen embr i t t l ement . " Hydr ogen embr i t t l ement causes t he
st eel t o f r act ur e al ong sheer pl anes mor e easi l y. Thus, t he
st r engt h of t he st eel f r ame i s gr eat l y di mi ni shed. A bui l der
who want s t he ut most i n st r engt h char act er i st i cs i n a f r ame
shoul d not have pl at i ng done.
PAI NTI NG TECHNI QUES
Thi s i s a r at her di f f i cul t subj ect . Pai nt i ng t akes a l ot
of pr act i ce and t her e r eal l y i sn' t any way t o gai n t he st eady
hand and necessar y smoot h movement s t o pai nt a f r ame f r oma
book. About al l t hat can be done i s t o l i st a f ew f i nal
hi nt s and l eave t he r est up t o t he r eader .
1. Pai nt wi t h t he gun about 20 t o 25 cmaway f r omt he wor k.
2. I nspect t he wor k f r equent l y f or r uns and or ange peel .
Remove i t f r omt he boot h and hol d i t up t o a br i ght
l i ght and l ook car ef ul l y. I f a r un devel ops, don' t
t ouch i t ! Car ef ul l y r ot at e t he f r ame and t r y t o get
gr avi t y t o r emove t he r un. I f t hat f ai l s, don' t t ouch
i t . Let i t dr y over ni ght and wet sand i t out t he next
day. Then r eshoot t he col or agai n. I f or ange peel i s
devel opi ng, check t he f l ui d cont r ol and sl ow down your
sweepi ng movement of your ar m.
3. Be car ef ul about goi ng over a spot t oo many t i mes. The
f or k cr own i s a pr obl emi n t hi s r espect .
4. Check t he backsi de of br aze- ons f or pai nt cover age.
Some pr obl emar eas ar e: t he t op of t he bi nder bol t , t he
t op of t he br ake br i dge, behi nd t he l ef t bot t ombr acket
gui de and t he f r ont s and backs of t op t ube cabl e
gui des.
5. When t he f r ame i s f i ni shed cl amp t he seat t ube pai nt i ng
handl e i n t he Par k st and and r ot at e t he f r ame ever y f i ve
or t en mi nut es.
6. Do not pai nt when you ar e t i r ed or upset !
7. El i mi nat e di st r act i ons ar ound you. Annoyi ng noi ses,
peopl e aski ng t oo many quest i ons, or a t el ephone can be
di f f i cul t t o cont end wi t h.
8. Don' t t r y t o cover ever yt hi ng i n one coat . Fi r st , do a
l i ght t ack coat . Then f i ni sh up about hal f an hour
l at er wi t h t he f i nal gl ossy coat .
11- 32
PATEREK MANUAL - SUPPLEMENTAL SHEET
FRAMEBUI LDERS' VARI ATI ONS:
Pg. 2- 3
Br azed- on f r ont der ai l l eur ; The new Shi mano Dur a- ace EX f r ont der ai l -
l eur f or 1985 wi l l be i nt er changeabl e wi t h Campagnol o.
Pg. 2- 5 t o 2- 6
Cant i l ever br ake set s; The new Sunt our XC power br akes ar e not i nt er -
changeabl e wi t h any ot her br and of cant i l ever . Seper at e mount i ng bosses
pr ovi ded by Sunt our must be br azed- on i nst ead of t he cant i l ever st uds
shown at t he bot t omof page 2- 5. Bel ow i s a dr awi ng showi ng t he di f f er ent
st yl e boss and t he appr oxi mat e l ocat i ons f or of f - r oad bi kes.
Pg. 2- 17 t o 2- 20
Chai nst ay br i dges; A smal l number of bot t ombr acket shel l manuf act ur er s
have i nt egr at ed t he chai nst ay br i dge r i ght i nt o t he cast i ng. These have onl y
appear ed at nat i onal bi ke shows as of J anuar y of 1985.
Pg. 2- 24 t o 2- 30
Seat cl ust er s; St r awber r y now sel l s a yoke shaped f i t t i ng t hat act s
as a combi nat i on br ake br i dge and seat cl ust er . Bel ow i s a sket ch. Not e t he
l ocat i on of t he bi nder f or t he seat post .
pg. 2- 34 t o 2- 35
Lug set s; Tange i s now mar ket i ng an i nvest ment cast l ug set . Li t t l e or
no r eami ng i s r equi r ed. Li t t l e or no cl ean- up i s r equi r ed. Shor t poi nt s and
no cut - out s.
Pg. 2- 34 t o 2- 35
Lug set s; Oht suya Medal i st l ugset s ar e avai l abl e f r omQual i t y Bi cycl e
Pr oduct s. These ar e i nvest ment cast wi t h shor t poi nt s and no cut - out s. They
can be best descr i bed i n one wor d; "pet i t e. " They r equi r e l i t t l e or no r eam-
i ng and ver y l i t t l e cl eab- up. The seat l ug has an i nt er nal r i mf or t he t op
edge of t he seat t ube t o but t up agai nst .
Pg. 2- 34 t o 2- 35
Lug set s; Lug set s ar e now avai l abl e f r omBi l l Davi dson. They ar e i n-
vest ment cast . Mi ni mumor der . . . . . 10 set s.
Pg. 2- 35 t o 2- 37
Bot t ombr acket shel l s; Tange i s now mar ket i ng an i nvest ment cast bot t om
br acket shel l . I t r equi r es l i t t l e or no r eami ng. I t ' s avai l abl e i n BSA specs
and t he machi ni ng on t he t hr eads and f aces i s excel l ent . The br and name i s
cast r at her deepl y i nt o t he under si de.
Pg. 2- 35 t o 2- 37
Bot t ombr acket shel l s; Oht suya Medal i st bot t ombr acket shel l s ar e avai l -
abl e f r omQual i t y Bi cycl e Pr oduct s. I t i s i nvest ment cast wi t h excel l ent
machi ni ng on t hr eads and f aces. Avai l abl e i n BSA specs. I t r equi r es onl y
moder at e r eami ng. I t di spl ays 2 cut out s; one bel ow t he downt ube and t he ot her
behi nd t he seat t ube.
Pg. 2- 35 t o 2- 37
Bot t omBr acket Shel l s; Bot t ombr acket shel l s ar e now avai l abl e f r om
Bi l l Davi dson. They ar e i nvest ment cast . Mi ni mumor der . . . . . . 10.
Pg. 2- 44 t o 2- 45
Dr opout s; A new set of Shi mano ver t i cal s ar e avai l abl e. They ar e l i st ed
as FE- SF- 22. They have r ai sed f aces, cut out s, and der ai l l eur hanger . They
ar e made of f or ged st eel and have 8 eyel et s. ( Same as FE- SF- 21 except wi t h
doubl e eyel et s)
Pg. 2- 49
A speci al t op t ube i s avai l abl e f r omCol umbus. I t has a cr ease r unni ng
al ong i t s si de. Thi s al l ows f or neat st or age of t he r ear br ake cabl e wi t h-
out t he use of cl i ps or br aze- ons. I t can be pur chased seper at el y and used
wi t h any t ube set .
Pg. 2- 64
Tube set s; Tange has r ecent l y i nt r oduced t he 1000 ser i es. Send t o
Shi mano f or mor e i nf or mat i on.
Pg. 2- 64
Tube set s; Tange has r ecent l y i nt r oduced t he 900 ser i es. Send t o
Shi mano f or mor e i nf or mat i on.
Pg. 2- 64
Tube set s; Tange has recently introduced the Infinity series of
tubing. Thi s i s a seamed t ubi ng t hat has t aper ed wal l s r at her t han but t ed
wal l s. Dur i ng col dwor ki ng, t he seams near l y di sappear
from sight and the
t ube t akes on al most t he same st r engt h pr oper t i es as seaml ess t ubi ng. Send
t o Shi mano f or mor e i nf or mat i on. The I nf i ni t y name comes f r omt he concept
t hat t he t ubes do not have a st ar t i ng or st oppi ng poi nt f or t he but t . I n
ef f ect , t hey ar e i nf i ni t el y butted.
TOOLS
Pg 6- 12
A Chadwi ck 28 adj ust abl e r eamer can be pur chased t o r eamt he f or k
cr own f or t he gener al pr ep ( See f i g 29 on pg3- 61) . A chadwi ck # 30 r eamer
can be pur chased t o r eamdamaged Br i t i sh or Fr ench bot t ombr acket shel l s
t o t he mi nor di amet er of I t al i an bot t ombr acket t hr eads. Equi val ent r eamer s
ar e avai l abl e f r omHKC and VAR.
Pg. 6- 12
An adj ust abl e si zi ng st and can be pur chased f r omBenot t o t o si mul at e
t he act ual f i t t hat a pr oposed f r ame wi l l have f or a cust omer . These ar e
avai l abl e onl y on a speci al or der basi s f r omI t al y and del i ver y t i me i s
l ong. They shoul d be used onl y as a sel l i ng ai d and not f or f r ame desi gn.
Recommended pr ocedur e i s t o use t hemi n conj unct i on wi t h t he Fi t Ki t and
t he compl et ed wor ki ng dr awi ng.
Pg. 6- 12
The SAPO f r ame al i gnment ki t can be pur chased f r omLee Kat z. Thi s ki t
al l ows t he bui l der t o check t he al i gnment of t he f or k, headt ube, f r ont t r i -
angl e, and r ear t r i angl e pr eci sel y. ( See Kat z i n t he r esour ce sect i on. )
RESOURCES:
Pg. 7- 7
SATTERLEE' S ( R)
2200 East Fr ankl i n Avenue
Mi nneapol i s, MN
55404
ph. 612- 370- 2511
Sat t er l ee' s has an ext ensi ve sel ect i on of pr eci si on t ool s. They car r y
t he St ar r et t , Chadwi ck, Uni on and ot her br ands. They wi l l shi p or der s UPS
- COD i f you have manuf act ur er s' number s r eady.
Pg. 7- 8
THE SI LVER TOOLBOX ( R)
717- 721 Mar shal l St r eet N. E.
Mi nneapol i s, AN
55413
ph 612- 379- 2217
They sel l a compl et e sel ect i on of f i ne f i ni shi ng t ool s such as r i f f l er s,
abr asi ves, and cut t i ng t ool s. Compl et e cat al ogues ar e avai l sbl e f or $2. 00.
Pg. 7- 5
GRANGER' S
( R)
2616 27t h Ave. So. -
Mi nneapol i s, AN
55406
ph. 612- 721- 5531
Gr anger ' s sel l s a compl et e l i ne of power t ool s such as dr i l l pr esses,
pneumat i c t ool s, di e gr i nder s, el ect r i c mot or s, compr essor s, wel di ng out f i t s,
et c. A compl et e cat al ogue i s avai l abl e.
Pg. 7- 4
CYCLE I MPORTS ( I , W)
P. O. Box 287
Cor ni sh, Mai ne
04020
ph. 207- 625- 8781
Cycl e I mpor t s sel l s a compl et e l i ne of f r amebui l di ng suppl i es i ncl udi ng
Reynol ds and Col umbus t ube set s, Ci nel l i mat er i al s, and Shi mano & Campag-
nol o dr opout s. They al so sel l i ndi vi dual Reynol ds and Col umbus t ubes. Send
f or cat al ogue and pr i ce l i st .
Pg. 7- 2
BI KE MACHI NERY ( H)
PRODUZI ONE MACCHI NE SPECI ALI
Vi a Sot t or i pa, 14/ A
Ser i at e ( BG) I t al y
ph. 035/ 299. 093- 24068
Bi ke Machi ner y manuf act ur es a compl et e l i ne of f r amebui l di ng f i xt ur es
and pr eci si on measur i ng f i xt ur es whi ch ar e set up wi t h hydr ol i cs and pneu-
mat i cs f or i ncr eased speed and ef f i ci ency. The pr oduct s ar e mar ket ed i n
t he U. S. A. t hr ough Pr i mo Consor i zi o under t he Ci nel l i name.
Pg. 7- 6
NI KKO SANGYO CO. , LTD. ( M)
14- 23, 4- Chome,
Shi r at or i , Kat sushi ka- ku
Tokyo, J apan
ph. ( 03) 601- 7616
Ni kko Sangyo manuf act ur es a compl et e l i ne of l ugs, I - pc. f or ks, bot t om
br acket shel l s, and si ngl e pi ece headt ube/ headl ug uni t s.
Pg. 7- 4
CYCLO GEAR COMPANY LTD. ( H)
Cr own Wor ks, Bal t i mor e Road, Per r y Bar r
Bi r mi nghamB42 1DP
Engl and
ph. 021- 356- 7411
Cycl o of f er s a l i ne of r easonabl y pr i ced f r amebui l di ng t ool s i n-
cl udi ng bot t ombr acket t aps, cr own cut t er s, f or k di es, and dr opuot
al i gni ng t ool s. Send f or l i st of Amer i can Di st r i but or s.
Pg. 7- 5
I SHI WATA SEI SAKUSHO CO. , LTD.
( M)
Head Of f i ce: 2- 19- 19 Shi ohama
Kawasaki - ku
Kawasaki , J apan
ph. 044- 266- 3934
I shi wat a manuf act ur es a compl et e l i ne of cycl e f r ame t ubi ng and
di st r i but es t hr ough a smal l number Amer i can di st r i but or s. Send f or a l i st
of t hose di st r i but or s.
Andrew
Hague
Manufacturers of quality pedal cycle components
FORK CROWN This crown has been designed by Andrew
Hague for the modern lightweight bicycle. It
is made for us by Midland Investment
Casting Ltd. in Kidderminster using our own
tooling. It is very strong. being made in EN8
steel and annealed and heat treated,
There is no superfluous metal which means
that it is one of the lightest crowns in the
world. During brazing the lackof
unnecessary mass makes it easy to avoid
overheating the forkblades and steering
column, thus ensuring a stronger pair of
forks.
The open shoulder allows expansion gases to
escape from inside the forkblades_ Brass can
be fed through the aperture as well as into
the bottom of the crown ensuring that there
is proper brass penetration and a good joint_
Please note that we recommend Reynolds
tubing and have followed their advice on
leaving a gap of four thousandths of an inch
between the blades and crown in order to
allow the brass to penetrate. Blades that
have to be hammered into a crown run the
riskof being dry jointed and pre-stressed
The crown is made to fit the continental
'oval style of blades. It is ideal for use with
753 tubing.
The investment casting has
a smooth surface finish needing no cleaning up which is of considerable benefit to the frame builder.
The shoulder is plugged by aluminium discs which we can engrave as you req uire. The discs can be fitted before or after painting. The
easiest method of fastening them in 4 with a small amount of adhesive. The uniq ue feature of the aluminium disc creates endless
opportunities to individualize the appearance of your bicycle.
The crown ,is supplied with forkblade l i
ners which can be used as they are or filed into fancy shapes.
MACHINED FRAME COMPONENTS
Our wide range of frame components is made with fully automatic eq uipment so that production costs are as low as possib l e and the
precision repeated consistently. Whether you want ten parts or a million we can meet your needs.
We are also able to undertake sub-contract engineering workwhich other companies are unable to handle because of the precision,
intricacy and q uantity req uired. If you thinkthat we can help please contact us. V i
s i tors are always welcome to Inspect our factory,
CABLE GUIDES AND STOPS
Bottom Bracket Tunnel
Sloping Sides Guide, with flat on the
bottom.
Cutaway Guide, with flat on the bottom.
Divers Helmet Guide without slot, mitred
to fit 1" tube.
Hexagonal Guide
Round Guide
Bottom Bracket Groove
Slotted Guide, with flat on the bottom.
Cutaway Stop, with flat on the bottom_
Divers Helmet Guide with slot, mitred
to fit 1" tube.
Hexagonal Stop
Round Stop
Grooved Guide, with flat on the bottom
FORK END EYELET
3/8" diamete
r
with a fl at on the bottom. This serves
as another fork end eyel et for mudguards or a pannier
carrier. Tapped M5 and suppl ied with a stainl ess steel
screw.
BOTTLE CAGE BOSS Recessed
Fits into a 7mm hol e in the frame tube so that the
top hardl y protrudes. Tapped M5. Suppl ied with
stainl ess steel screw,
BOTTLE CAGE BOSS Straight
BOTTLE CAGE BOSS With Waist
Tapped M5. Mounts on the frame tube. 3/8"-
This is a l ight version of the straight boss The waist
diameter. Suppl ied with stainl ess steel screw,
makes it suitabl e for brazing to the upper seat stays
as a pannier carrier mounting, Tapped M5 and
suppl ied with a stainl ess steel screw.
BRAKE BRIDGES
We have a special machine which was made to
our own design to mitre brake and chain stay
bridges to any exact l ength, at any angl e to fit
any diameter. It you are making more than a
hundred frames of any one size it wil l be
cheaper to l et us make them on the bridge
machine than to do it yoursel f. We can al so
make bridges for mixte frames
One piece bridge, made from
square bar , hol l ow, and
suppl ied with two recessed
M6 nuts
,
one for the brake
bridge and the other for the
fork crown
Reinforcing piece to f i t around the
brake bridge. Avail abl e in three sizes
to fit 1/2". 7/16" or 3/8" tubing.
These have a neat Wel l ed shape.
Pg. 7- 5
ANDREWHAGUE CYCLES LTD.
( M, W, F)
CwmDr aw I ndust r i al Est at e
Ebbw Val e, Gwent . NP3 5AE
Wal es
Br i t i sh I sl es
ph. 0495 305915
Andr ew Hague manuf act ur es a compl et e l i ne of f or k cr owns, sl ugs,
br aze- ons, br i dges, ai d f r amebui l di ng f i xt ur es. Any of t he Hague pr oduct
l i ne can be or der ed
f r omEngl and or t hr ough Phi l Wood
( See Wood, Phi l i n
t he r esour ce sect i on of t hi s book. ) .
P
A T
E
R E K C O M P U T E R P R O G R A M S
T H E . P A T E R E K C O M P U T E R P R O G R A M S h a v e b e e n d e s i g n e d m a t h e m a t i c a l l y t o
g e n e r a t e g e a r c h a r t s . c a l c ul a t e s po ke l e n g t h s , a n d g e o m e t r i c a l l y
d e s i g n c us t o m b i c y c l e f r a m e s . Be c a us e o f t h e n a t ur e o f t h e pr o b l e m s
t h e s e pr o g r a m s a t t e m pt t o t a c kl e t h e r e i s a c e r t a i n a m o un t o f e r r o r
i n v o l v e d i n t h e s po ke l e n
g
t h a n d f r a m e g e o m e t r y pr o g r a m s . T h e e r r o r
t h a t e xi s t s i s a s s o c i a t e d wi t h h o w e f f e c t i v e l y t h e us e r c a n m a ke t h e
n e c e s s a r y m e a s ur e m e n t s t h e pr o g r a m c a l l s f o r . T h e r e a r e t h r e e
m e a s ur e m e n t s t h a t c a n m a ke o r b r e a k t h e f r a m e g e o m e t r y pr o g r a m :
I n s e a m m e a s ur e m e n t - - - I n c o r r e c t m e a s ur e m e n t o f t h e r i d e r ' s
i n s e a m wi l l r e s ul t i n t h e wr o n g s e a t t ub e l e n g t h f o r t h e
r i d e r t h e f r a m e i s b e i n g d e s i g n e d f o r . C h e c k T H E P A T E R E K
M A NU A L o r T H E FI T K I T DI R E C T I O N M A NU A L f o r t h e pr o pe r m e t h o d
i n m a ki n g t h i s m e a s ur e m e n t .
T o r s o M e a s ur e m e n t & a r m m e a s ur e m e n t - - I n c o r r e c t m e a s ur e m e n t
o f t h e s e t wo v a r i a b l e s wi l l r e s ul t i n t h e t o p t ub e b e i n g o f
a n i n c o r r e c t l e n g t h . C h e c k T H E P A T E R E K M A NU A L o r T H E FI T
K I T M A NU A L f o r t h e pr o pe r m e t h o d i n m a ki n g t h e s e
m e a s ur e m e n t s .
T h e s po ke l e n g t h pr o g r a m d e
p
e n d s o n t h e us e r m a ki n g s e v e r a l
a c c ur a t e m e a s ur e m e n t s . H o we v e r , o n e o f t h e s e m e a s ur e m e n t s i s f a r m o r e
c r i t i c a l t h a n t h e o t h e r s :
R i m d i a m e t e r - - T h i s m e a s ur e m e n t c r i t i c a l t o t h e o pe r a t i o n
o f t h i s pr o g r a m . A d e v i c e m us t b e m a d e t o a c c ur a t e l y f i n d
t h e r i m d i a m e t e r e a c h a n d e v e r y t i m e . Do n o t us e t h e
Wh e e l s m i t h d e v i s e ! I t wo r ks f o r t h e i r pr o g r a m b ut wi l l n o t
g i v e r e a d i n g s t h a t a r e a c c ur a t e f o r t h i s pr o g r a m .
T h e g e a r c h a r t pr o g r a m wi l l pr e s e n t n o s uc h
p
r o b l e m s a n d s h o ul d
g e n e r a t e a c c ur a t e r e s ul t s e v e r y t i m e .
Due t o t h e f a c t t h a t t h e s e pr o g r a m s r e l y h e a v i l y o n t h e us e r ' s
a b i l i t i e s t o m e a s ur e pr o pe r l y , T h e Fr a m e b ui l d e r s ' G ui l d , R o b e r t Wi e k,
J o h n C o r b e t t , T i m P a t e r e k, a n d J o e H e s s e d o n o t a c c e pt a n y l e g a l
l i a b i l i t i e s d ue t c f a ul t y f r a m e d e s i g n r e s ul t i n g f r o m i n a c c ur a c i e s i n
b o d y m e a s ur e m e n t s .
M a ke a f e w t r i a l r un s o f t h e pr o g r a m s b e f o r e f ul l y i m pl e m e n t i n g
t h e m i n y o ur b us i n e s s . M a ke s ur e y o u a r e h a ppy wi t h t h e r e s ul t s
b e f o r e y o u i n t r o d uc e y o ur c us t o m e r s t o " H I - T E C H " b i ke d e s i g n .
Fo r y o ur c o n v e n i e n c e t h e s e pr o g r a m s a r e n o t pr o t e c t e d a g a i n s t
c o py i n g s o t h a t y o u c a n m a ke b a c k- up c o pi e s . P l e a s e d o n ' t pi r a t e o ur
pr o g r a m s . S e n d t h e b us i n e s s o ur wa y . We wi l l a ppr e c i a t e i t .
Fo r upd a t e d v e r s i o n s o f t h e pr o g r a m , s e n d y o ur d i s k a n d $5. 00 t o :
T h e Fr a m e b ui l d e r s ' G ui l d
R t . 2, Bo x 234
R i v e r Fa l l s , WI 54022
We wi l l s e n d y o u a n upd a t e d v e r s i o n o f t h e pr o g r a m . T h e n e xt upd a t e d
v e r s i o n wi l l b e a v a i l a b l e i n De c e m b e r o f 1986.
TO OBTAIN THE IBM
COMPATIBLE DISK FOR THIS
PROGRAM SEND $29.95 TO:
KERMESSE DISTRIBUTORS
464 CENTRAL AVE. UNIT #2
HORSHAM, PA. 19044
215-672-0230
I NSTRUCTI ONS FOR SPOKE CALCULATI ON PROGRAM
Thi s comput er pr ogr ami s desi gned t o wor k on Appl e I l e, I I c, or I BM
compat abl e comput er s. Check t he l abel on t he di sket t e t o see t hat you have
t he cor r ect pr ogr amf or your comput er .
STEP 1:
Boot up your comput er as you usual l y do. THE PATEREK PROGRAMS ar e not
boot - up di sks.
STEP 2:
I nser t THE PATEREK PROGRAM di sk i nt o dr i ve 1.
STEP 3:
Type t he f ol l owi ng command:
PATEREK ( r et ur n)
STEP 4:
You shoul d now see t he openi ng menu whi ch di spl ays t he name PATEREK i n
f l ashi ng l et er s. On t he menu ar e t hr ee choi ces;
IS} poke l engt h
( G}ear char t s
( E) xi t t o DOS
Choose S t o get i nt o t he spoke l engt h pr ogr am.
STEP 5:
The pr ogr amwi l l ask whet her you want t o ent er dat a i n Met r i c uni t s or
Engl i sh uni t s. Choose M or E.
STEP 6:
When ent er i ng dat a, al ways use t he same uni t s. I n Met r i c i t i s best t o
use Mi l l i met er s. I n Engl i sh use t housandt hs of an i nch. Ent er i ng a
measur ement i n cent i met er s af t er usi ng mi l l i met er s wi l l cuase al l answer s t o
be i ncor r ect . Ent er i ng a measur ement i n f eet af t er usi ng i nches wi l l cause
al l answer s t o be i ncor r ect .
HUB WI DTH i s measur ed acr oss
t he out si des of t he f l anges.
( See t he di agr amat t he
r i ght . )
HUB DI AMETER i s measur ed f r om
t he cent er of a hol e on one
si de of t he f l ange t o a hol e
cent er di r ect l y on t he ot her
si de of t he same f l ange. ( See
page 12- 2 of Sut her l and' s
Handbook. )
RI M DI AMETER i s measur ed f r omt he t heor et i cal poi nt wher e t he end of t he
spoke pokes t hr ough a hol e i n one si de of t he r i mt o t he same t heor et i cal
poi nt on t he ot her si de of t he r i m. ( See page 12- 17 of Sut her l and' s
Handbook. )
NUMBER OF SPOKES i s si mpl y how many spokes t her e wi l l be i n t he wheel . e. g.
24, 28, 32, 36, 48 et c.
CROSSES I N PATTERN i s how many cr osses t her e ar e i n t he spoke pat t er n. e. g. 3
cr oss, 4 cr oss, et c. Be car ef ul , t hi s pr ogr amwi l l gi ve r esul t s f or pat t er ns
t hat ar e not possi bl e. Keep i n mi nd t hat wheel s wi t h l ess spokes can' t be
bui l t wi t h l ar ge number s of cr osses.
STEP 7:
Thi s pr ogr amwi l l gi ve i mmedi at e r esul t s. I t wi l l di spl ay spoke l engt hs
f or an undi shed f r ont wheel , a f i ve speed r ear wheel , and a si x speed r ear
wheel . I t wi l l t hen ask i f you want t o comput e anot her . Ent er Y t o go
t hr ough t he pr ogr amagai n. Ent er N t o exi t t o t he mai n MENU.
I MPORTANT:
t he r esul t s t hi s pr ogr amwi l l del i ver ar e onl y as good as t he measur i ng
t hat i s done t o obt ai n HUB WI DTH, HUB DI AMETER, and RI M DI AMETER. As you get
mor e accust omed t o measur i ng t hese i t ems, t he r esul t s wi l l become mor e
accur at e.
I NSTRUCTI ONS FOR GEAR CHART PROGRAM
STEP 1:
Boot up your machi ne as you usual l y do. THE PATEREK PROGRAMS ar e not
boot - up di sks.
STEP 2:
I nser t THE PATEREK PROGRAM i nt o dr i ve 1.
STEP 3:
Type t he f ol l owi ng command:
PATEREK ( r et ur n)
STEP 4:
you shoul d see t he openi ng menu whi ch di spl ays t he name PATEREK i n
f l ashi ng l et t er s. On t he menu ar e t hr ee choi ces;
{ S}poke l engt h
{ G} ear char t s
{ E}xi t t o DOS
Choose G t o get i nt o t he gear char t pr ogr am.
STEP 5:
The pr ogr amwi l l ask whet her you want t o ent er dat a i n Met r i c uni t s or
Engl i sh Uni t s. Choose M or E.
SPROCKET 8
1 8 22 26
81.0 66.3 56.1
73.5 60.1 50.9
58.5 47.9 40.5
ENTER ACTION DESIRED
( % } Grid Percentages
{C} hange Gears
{E} nd Process
LW Sp ###.#
54 13 112.2
49 13 101.8 14
: 54 15 97.2
- - - - +4-1 15 88.2 13
: 54 18 01.0 10
: 39 13 81.0 0
: 49 18 73.5 10
% 39 15 70.2 4
: 54 22 66.3 4
: 49 2260.18
: 39 18 58.5 1
% 54 26 56.1 3
| 49 26 50.9 7
: 39 22 47.9 4
79_26 40.5 10
C
H
A
: 13
+ - - - - - V .
1 5
%
I 54 : 112.2 97.2
N
W
H 49 : 101.8 88.2
E
E
L
S 79 : 81.0 70.2
MENU GRI D TEETH GEAR PERCENT
STEP 6:
You wi l l be asked t o ent er t he wheel di amet er . Ent er i t i n i nches i f you
chose Engl i sh. Ent er i t i n Cent i met er s i f you chose Met r i c. Pr ess r et ur n.
STEP 7:
You wi l l be asked how many spr ocket s t her e ar e on t he r ear hub. You can
choose as many as 7 spr ocket s f or t he r ear . Pr ess r et ur n.
STEP 8:
You wi l l be asked how many chai nwheel s t her e ar e on t he f r ont . You can
choose as many as 3 chai nwheel s. Pr ess r et ur n.
STEP 9:
You wi l l now see a gr i d on t he l ef t hand si de of t he scr een wi t h t he
cur sor bl i nki ng i n t he f i r st l ocat i on on t he l ef t . Type i n t he number of
t eet h on t he smal l est spr ocket desi r ed and t hen pr ess r et ur n. The cur sor
moves t o t he next sl ot . Ent er t he number of t eet h desi r ed f or t he next t o
t he smal l est spr ocket and pr ess r et ur n. The pr ogr amwi l l aut omat i cal l y
advance t hr ough t he gr i d t i l l al l of t he spr ocket s ar e ent er ed. I t wi l l t hen
pr oceed t o t he chai nwheel por t i on of t he gr i d. Ent er chai nwheel s t he same
way as you ent er ed spr ocket s. When t he l ast chai nwheel si ze i s ent er ed, t he
pr ogr ami s execut ed.
STEP 10:
Thi s i s what you wi l l see on t he scr een:
THE FRAME BUILDERS" GUILD
Gear Charts
MENU - The menu wi l l al l ow you t o r et ur n t o t he mai n menu by choosi ng E. I t
wi l l al l ow you t o al t er spr ocket and chai nwheel si zes by choosi ng C. I t wi l l
al l ow you t o see an over vi ew of t he per cent age di f f er ences on t he gr i d by
choosi ng %. I t wi l l al l ow you t o get a pr i nt out of t he gear s you have chosen
by pr essi ng P.
GRI D - The gr i d di spl ays t he gear s chosen i n an ar r ay t hat i s easy t o r ead.
On t he r i ght of t he scr een, you wi l l see anot her ar r ay of number s. The
number s appear i ng i n t he t hr ee col umns ar e al l of t he gear s you have chosen
i n decendi ng or der . The t hr ee col umns can be br oken down as f ol l ows:
TEETH - Thi s col umn t el l s whi ch t oot h combi nat i ons make up t hat par t i cul ar
gear . Fi r st i s chai nwheel si ze, t hen spr ocket si ze.
GEAR - Thi s col umn t el l s t he val ue of each gear . ( Mul t i pl yi ng t hi s val ue by
Pi wi l l gi ve t he di st ance t r avel ed i n t hat gear i n one pedal r evol ut i on. )
PERCENT - Thi s col umn gi ves t he per cent of change f r omone gear t o t he next
as you decend t hr ough t he gear s. Thi s i s pr obabl y t he most i mpor t ant col umn.
You wi l l want t o l ook f or l ar ge per cent age j umps or smal l per cent age j umps
and al t er t he number s of t eet h t o el i mi nat e t hese i r r egul ar i t i es.
STEP 11:
Check out t he spr ocket s and chai nwheel s you have chosen and see how t hey
appear i n t he pr ogr am. I f you l i ke t he set - up, pr ess P t o get a pr i nt out .
I f you don' t l i ke t he set - up, choose C f r omt he menu and make t he changes you
want . Keep doi ng t hi s t i l l you ar r i ve at t he combi nat i on you want . What
used t o t ake hour s wi t h a hand cal cul at or can now be done i n about 15
mi nut es.
STEP 12:
To end t he pr ocess, choose E.
SPECI AL FEATURES:
CROSS OVER GEARS ar e hi ghl i ght ed so t hat you can t ake t hemi nt o consi der at i on
when set t i ng up your gear s. A l ow per cent age f i gur e i mmedi at el y bef or e or
af t er a cr ossover gear shoul d not be wor r i ed about . A l ar ge per cent age
change bef or e or af t er a cr oss over gear shoul d be wor ked wi t h.
CHAI NWHEEL ORDER i s put i n decendi ng or der on t he gr i d. The pr ogr amdoes
t hi s aut omat i cal l y even i f you ent er t he chai nwheel si zes i n r ever se or der .
I n t hi s way, t he ar r ay i s mor e easi l y r ead af t er t he pr ogr ami s execut ed.
I NSTRUCTI ONS FOR FRAME GEOMETRY PROGRAM
The PATEREK f r ame geomet r y pr ogr ami s onl y avai l abl e f or t he I BM
PC and PC compat i bl es. Be sur e your machi ne i s compat i bl e wi t h I BM
bef or e at t empt i ng t o use t hi s pr ogr am.
STEP 1:
Boot up your machi ne as you usual l y do. THE PATEREK PROGRAMS ar e
not boot - up di sks.
STEP 2:
I nser t THE PATEREK PROGRAM di sk i nt o dr i ve 1.
STEP 3:
Type t he f ol l owi ng command:
PATEREK ( r et ur n)
STEP 4:
You shoul d see t he opei ng menu whi ch di spl ays t he name PATEREK i n
f l ashi ng l et t er s. On t he menu ar e f our choi ces;
S poke l engt h
G ear char t s
F r ame geomet r y
E xi t t o DOS
Choose F t o get t he f r ame geomet r y pr ogr am.
STEP 5:
The pr ogr amwi l l ask you i f you want t o use R i der s body
measur ement s or B i ke' s known measur ement s.
Choose R i f you ar e act ual l y measur i ng t he r i der f or whomt he
f r ame i s bei ng bui l t . Go t o STEP 6.
Choose B i f you know t he di mensi ons of t he f r ame t o be bui l t
or i f you ar e obt ai ni ng t he di mensi ons f r omTHE FI T KI T. I f
you choose B, t he pr ogr amwi l l ask you t o choose R t o desi gn
a r aci ng f r ame, S f or spor t / t our i ng, T f or t our i ng, or M f or
mount ai n. ( The pr ogr amwi l l aut omat i cal l y desi gn a mount ai n
f r ame wi t h a 1- 1/ 4" di amet er down t ube and a 1- 1/ 8" di amet er
t op t ube. ) Af t er choosi ng t he f r ame st yl e a new di spl ay wi l l
come on t he scr een aski ng you t o make t he f ol l owi ng ent r i es:
Seat t ube l engt h
Top t ube l engt h
Wheel r adi us
*For k cr own t hi ckness
**Lower st ack hei ght
***HT/ DT i nt er cept poi nt
Make al l ent r i es t o t he near est t ent h of a cent i met er .
Now t hat t he known di mensi ons have been ent er ed,
t he pr ogr amwi l l comput e t he unknown di mensi ons on
t he r i ght si de of t he scr een.
Go t o STEP 10.
STEP 6:
The pr ogr amwi l l ask you whi ch st yl e of f r ame you want t o desi gn.
Choose R f or a r aci ng f r ame, S f or spor t / t our i ng, T f or t our i ng, or M
f or mount ai n ( The pr ogr amwi l l aut omat i cal l y comput e mount ai n bi kes
wi t h 1- 1/ 4" down t ubes and 1- 1/ 8" t op t ubes. ) Do not pr ess r et ur n.
STEP 7:
The pr ogr amwi l l ask whet her you want t o ent er dat a i n Met r i c or
Engl i sh. ( Thi s opt i on i s f or r i der ' s body measur ement s onl y. Af t er
ent er i ng t hose measur ement s, t he pr ogr amwi l l aut omat i cal l y r ever t t o
Met r i c f or t he r est of t he sessi on. ) I f you choose Met r i c, ent er al l
body measur ement s i n cent i met er s and ki l ogr ams. I f you choose Engl i sh,
ent er al l body measur ement s i n i nches and pounds. The measur ement s
ar e as f ol l ows:
Hei ght - - i n st ocki ng f eet
Wei ght - - Wi t hi n 3%accur acy i s succi ci ent .
I nseam- - Up t i ght i n t he cr ot ch i n st ocki ng f eet
Tor so - - See page 1- 6 of THE PATEREK MANUAL.
Ar m - - See page 1- 6 of THE PATEREK MANUAL.
Pr ess r et ur n af t er each ent r y.
STEP 8:
The pr ogr amwi l l now ask t he wheel r adi us you i nt end t o use on
t hi s f r ame. ( Thi s i ncl udes t he t i r e r adi us. ) Ther e ar e t wo pr ompt s
at t he bot t omof t he scr een. You may choose one of t hose or ent er one
of your own. I t must be ent er ed i n cent i met er s. Pr ess r et ur n. You
wi l l now see a scr een di spl ay showi ng al l of t he known measur ement s
f or t he pr oposed f r ame.
STEP 9:
You ar e now r equi r ed t o ent er t he f ol l owi ng t o t he near est t ent h
cent i met er :
*For k cr own t hi ckness
**Lower st ack hei ght
***HT/ DT i nt er cept poi nt
Pr ess r et ur n af t er each ent r y. Af t er t he l ast ent r y, t he comput er
wi l l comput e t he unknowns on t he r i ght si de of t he scr een.
*To f i nd f or k cr own t hi ckness, see page 1-17 of THE
PATEREK MANUAL.
**To f i nd l ower st ack hei ght , see l et t er C on page
14- 7 of Sut her l and' s Handbook.
***To f i nd HT/ DT i nt er cept poi nt , see page 1- 17 of
THE PATEREK MANUAL.
STEP 10:
Bef or e goi ng on wi t h t he pr ogr am, exami ne t he scr een di spl ay. Al l
of t he known di mensi ons ar e on t he l ef t si de and al l of t he comput er
gener at ed unknowns ar e on t he r i ght si de. Not e how t he knowns ar e
number ed i n f i el ds f r om1 t o 13. Fi el ds 1 and 2 wer e gener at ed by
ent er i ng t he r i der ' s body measur ement s. Fi el ds 3 t hr ough 8 and 10 ar e
val ues assi gned t o t he st yl e of f r ame you chose. Fi el d 9 was chosen
di r ect l y by you. Fi el d 11 i s due t o t he f or k cr own you have chosen t o
use on t hi s f r ame. Fi el d 12 i s due t o t he headset you i nt end t o use on
t hi s f r ameset . Fi el d 13 i s due t o t he l ug set you chose t o use f or
t hi s f r ameset . I n about t he mi ddl e of t he scr een you ar e t ol d how
much cl ear ance you wi l l have bet ween t he f r ont t i r e and t he down t ube
and t he cl ear ance bet ween t he r ear t i r e and t he seat t ube. I f you do
not l i ke t he i dea t hat many of t he var i abl es wer e pr edet er mi ned f or
t hi s f r ame, you can change any f i el d except #5 and t he pr ogr amwi l l
r ecomput e a new set of unknowns. ( The onl y way t o al t er f i el d #5 i s
t o al t er your i ni t i al met hod of measur i ng t he r i der ' s i nseam. )
At t he bot t omof t he scr een you wi l l see t hi s pr ompt :
Ent er i nput f i el d ## t o change or 99 t o end pr ocess
I f you want t o change any of t he 13 f i el ds ( except #5) , t ype t he
number of t hat f i el d and t hen pr ess t he r et ur n key. Ther e i s now a
pr ompt at t hat l i ne. Ent er t he desi r ed di mensi on i n degr ees t o t he
near est t ent h or cent i met er s t o t he near est t ent h. Then pr ess r et ur n.
You may do t hi s any number of t i mes wi t h any f i el d except #5 and t he
comput er wi l l begi n t o gener at e new dat a. When you ar e sat i sf i ed wi t h
your r esul t s, ent er 99 and pr ess r et ur n. You wi l l now see a new menu
t hat l ooks l i ke t hi s:
M = Ret ur n t o menu
T = Comput e t oe cl i p over l ap
G = Pr i nt Geomet r i cal specs.
C = Pr i nt component l i st
STEP 11:
By choosi ng M, you wi l l r et ur n t o t he mai n menu. Doi ng t hi s wi l l
wi pe out al l dat a on t hi s f r ameset and you wi l l have t o st ar t al l
over . Goi ng back t o t he mai n menu wi l l al l ow you t o r un one of t he
ot her PATEREK PROGRAMS.
STEP 12:
By choosi ng T, you can comput e t oe cl i p over l ap f or t hi s
par t i cul ar f r ameset . You wi l l be asked f or t he f ol l owi ng i nput :
Lat er al of f set - - t hi s i s t he di st ance f r omt he
cent er l i ne of t he f r ameset t o t he cent er l i ne of
t he t oe cl i p. ( Campagnol o cr anks and pedal s ar e
appr oxi mat el y 12cmon t he l ef t si de. )
Toe cl i p and pedal - - t hi s i s t he measur ement f r om
t he cent er l i ne of t he pedal spi ndl e t o t he i nsi de
f ace of t he f r ont of t he t oe cl i p. Exampl es:
Campagnol o pedal wi t h a shor t t oecl i p i s 7. 5cm,
wi t h a medi umt oe cl i p i s 9cm, wi t h a l ong t oe cl i p
i s 10. 5 cm.
Cr ank l engt h - - t hi s i s t he l engt h of t he cr ank ar m
you ar e usi ng IN CENTIMETERS. For i nst ance, i f you
ar e usi ng 165mmcr anks, ent er 16. 5.
Pr ess t he r et ur n key af t er each ent r y.
Af t er t he cr ank l engt h ent r y t he t oe cl i p i nf or mat i on wi l l be
expr essed as a cl ear ance or i nt er f er ence. I f you want t o change t he
desi gn of t he f r ameset t o cor r ect t oe cl i p over l ap, pr ess t he # key
and goe back t o STEP 10.
STEP 13:
By choosi ng G, you can get a geomet r i cal spec sheet pr i nt out .
The pr ogr amwi l l f i r st ask f or a hub wi dt h. ( Thi s
i s f or your conveni ence on t he pr i nt out . ) Common
hub wi dt hs ar e 12cmf or a f i ve speed, 12. 6cmf or a
si x speed, and 13cmf or a mount ai n bi ke or dr um
br ake. Pr ess r et ur n.
The pr ogr amwi l l t hen ask you t o ent er t he
cust omer ' s name, addr ess, and phone number . ( an
addi t i onal l i ne i s al l owed f or a l ong addr ess or a
busi ness addr ess. ) Pr ess r et ur n af t er each ent r y.
The comput er wi l l now pr i nt out a cust omwor k or der wi t h al l of
t he necessar y geomet r i cal specs, name, addr ess, et c. Not e at t he
bot t omof t he pr i nt out i s a r ecommendat i on f or t he l i ght est t ubi ng t o
use f or t hi s r i der . Thi s i s based on t he r i der ' s wei ght t hat was
ent er ed ear l i er .
I f you want t o go back and make changes agai n t o do a di f f er ent
pr i nt out , pr ess t he # key and go back t o STEP 10.
STEP 14:
By choosi ng C, you can pr i nt up a component l i st f or t hi s
f r ameset .
At t hi s poi nt t he comput er wi l l pr ompt you t hr ough
al l of t he f r ame component s such as; l ugs, t ubi ng,
bot t ombr acket , et c. Si mpl y use t he keyboar d l i ke a
t ypewr i t er and pr ess r et ur n af t er each ent r y. When
you get t o t he bot t omof t he l i st , you wi l l be
asked i f t her e ar e any changes t o be made. I f YES,
t ype Y f ol l owed by r et ur n. Thi s wi l l al l ow you t o
go t hr ough t he l i st agai n. I f you want t o change an
i t em, do so and pr ess r et ur n. I f you don' t want t o
change an i t em, j ust pr ess r et ur n. I f t her e ar e no
f ur t her changes t o be made when you r each t he end
of t he l i st t ype N f ol l owed by r et ur n.
Now, i n exact l y t he same way, you wi l l be pr ompt ed
t hr ough t he br aze- on l i st . I f you do not wi sh t o
use a par t i cul ar br aze- on, pr ess r et ur n f or t hat
i t em. When you come t o t he end of t he l i st and
t her e ar e no f ur t her changes t o be made, t ype N
f ol l owed by r et ur n.
You may now l i st addi t i onal br aze- ons and speci al
r equest s. I f t her e ar e none, j ust t ype r et ur n a
f ew t i mes t i l l t he pr i nt out st ar t s.
An addi t i onal f eat ur e of t he component pr i nt out i s
a wor ksheet f or bi cycl e component s such as cr anks,
t i r es, t oe cl i ps et c. So, when t he comput er
f i ni shes up wi t h page 2, l et i t cont i nue on t o
pr i nt out page 3.
STEP 15:
To pr oper l y l og of f f r omt he f r ame geomet r y pr ogr am, choose M f r om
t he menu. Thi s t akes you back t o t he mai n menu. Then choose E. Thi s
wi l l al l ow you t o exi t t o DOS.
HELP LI ST FOR FORK CROWN THI CKNESSES AND HT/ DT I NTERCEPT POI NTS
COMMON FORK CROWN THI CKNESSES
Henr y J ames 1. 9cm
Davi dson 1. 6cm
QBP 1. 7cm
Ci nel l i
MCA , Tr at t o & SC 1. 6cm
CCA & CC 1. 5cm
SCA 1. 45cm
COMMON HT/ DT I NTERCEPT POI NTS
Henr y J ames 1. 0cm
Davi dson . 75cm
QBP . 65cm
Ci nel l i . 6cm
P LA NS FO R FI XT U R E S
T h e f o l l o wi n g 21 pl a t e s a r e a s e t o f t e c h n i c a l l i n e d r a wi n g s
g i v i n g a l l d i m e n s i o n s a n d s pe c i f i c a t i o n s a n d d i m e n s i o n s o f t h e
f r a m e b ui l d i n g f i xt ur e s s h o wn t h r o ug h o ut T H E P A T E R E K M A NU A L. T h e y
a r e d o n e wi t h t h e pe r s o n i n m i n d wh o h a s d a b b l e d i n f r a m e b ui l d i n g
a n d wa n t s t o m a ke a s ub s t a n t i a l f i n a n c i a l c o m m i t m e n t . I f b ui l t
pr o pe r l y , t h e s e f i xt ur e s wi l l pr o d uc e f r a m e s t h a t a r e a l i g n e d
we l l . M a n y c o r n e r s c a n b e c ut i n pr o d uc i n g t h e s e f i xt ur e s .
H o we v e r , i n d o i n g s o , t h e f i n a l qua l i t y o f t h e f r a m e s i s i n
j e o pr o d y .
I f a n y c o n f us i o n a r i s e s a s t o wh a t t h e s e f i xt ur e s d o o r l o o k l i ke ,
i s o m e t r i c s a n d ph o t o s a ppe a r i n n um e r o us l o c a t i o n s o f T H E P A T E R E K
M A NU A L.
C o n s i d e r i n g t h a t a m a j o r i t y o f t h e b i c y c l e i n d us t r y i s i n m e t r i c ,
o n e m a y wo n d e r wh y t h e s e pl a n s a r e i n E n g l i s h s pe c i f i c a t i o n s . T h e
e xpl a n a t i o n i s e a s y . T h e s e a r e pl a n s f o r a l o c a l j o b s h o p t o us e .
T r y wa l ki n g i n t o a s m a l l m a c h i n e s h o p wi t h a s e t o f m e t r i c pl a n s
a n d s e e wh a t h a ppe n s .
T h e r e a r e n um e r o us n ut s a n d b o l t s us e d i n t h e m a ke - up o f t h e s e
f i xt ur e s . Li t t l e o r n o s pe c s a r e g i v e n o n t h e s e i t e m s . S pe c s
s h o ul d b e a b l e t o b e d e r i v e d f r o m a c o m b i n a t i o n o f i s o m e t r i c
d r a wi n g s a n d c o r r e s po n d i n g t h r e a d s pe c s o n t h e d r a wi n g s .
Be f o r e a t t e m pt i n g t o pr o d uc e a n y t h i n g e l s e , t h e d um m y h ub s s h o ul d
b e c o n s t r uc t e d f i r s t . P a r t s 9 & 10 a n d pa r t s 3 & 4 s h o ul d b e m a d e
i n c o n j un c t i o n wi t h e a c h o t h e r .
C e r t a i n m a t e r i a l s a r e r e c o m m e n d e d f o r e a c h pi e c e . C a r e f ul
c o n s i d e r a t i o n wa s g i v e n t o t h e s e r e c o m m e n d a t i o n s a n d i n m o s t c a s e s
d e pa r t ur e f r o m t h e s e r e c o m m e n d a t i o n s i s n o t a d v i s e d .
I n T H E P A T E R E K M A NU A L t h e r e a r e n d j i g , h e a d t ub e s t a b i l i ze r b a r
a n d b o t t o m b r a c ke t j i g a r e s h o wn s e pe r a t e l y . T h e s e pl a n s h a v e
i n c o r po r a t e d a l l t h r e e i t e m s i n t o o n e un i t .
I t i s pl a i n t o s e e t h a t un l i ke T H E P A T E R E K M A NU A L, t h e s e s h e e t s
a r e pr i n t e d o n l y o n o n e s i d e . T h i s h a s b e e n d o n e s o t h a t t h e
pl a t e s c a n b e m o r e e a s i l y ke pt t r a c k o f d ur i n g pr o d uc t i o n .
La s t o f a l l , i t i s t h e a ut h o r ' s c o n t e n t i o n t h a t m a n y o f t h e s e
f i xt ur e s a r e i n t h e pub l i c d o m a i n . T h e r e m a i n d e r o f t h e m a r e
o r i g i n a l wo r k o f t h e a ut h o r a n d n o o n e s h o ul d b e a b l e t o c l a i m a
pa t e n t o n t h e m . H o we v e r , t h e d r a wi n g s t h e m s e l v e s a r e c o py r i g h t e d
a n d t h e P A T E R E K n a m e i s a t r a d e m a r k. A n y o n e i s we l c o m e t o b ui l d
a n d m a r ke t a s m a n y o f t h e s e f i xt ur e s a s t h e y l i ke wi t h n o n e e d t o
pa y a n y r o y a l t i e s t o T i m P a t e r e k. R e pr o d uc t i o n a n d d i s t r i b ut i o n
o f t h e pl a n s t h e m s e l v e s i s e xpr e s s l y pr o h i b i t e d . U s e o f t h e
P A T E R E K n a m e i n a n y m a n n e r i n t h e m a r ke t i n g o f t h e s e f i xt ur e s i s
e xpr e s s l y pr o h i b i t e d .
1
nal Material: T-6 aluminum or 1 020 steel
BASE FOR REAR END
Drawn by: Tim Paterek Scale: 1/4 size Tolerances; _ + 1/6 4
"-
fractional, t.002 - deci
3
4
5
6
7
8
9
10
11
12
1 .320"OD
LEFT HAND BOTTOM BRACKET PLUG
13
1 .320"OD
RIGHT HAND BOTTOM BRACKET PLUG
Drawn by: Tim Paterek
Tolerance: 1 1 /64"- fract. ,t.002"- dec.
Scale: full size
Material: 1 020 steel or 306 stainless
.51 56"ID
5"
1 OD
Drawn by: Tim Paterek
Tolerances: t1 /64"-fract.,.002"-dec.
Scale: full size
Material: 1 020 steel or 306 stainless
14
15
17
18
DUMMY HEADSET - LOWER PORTION
DUMMY HEADSET - UPPER PORTON
Drawn by: Tim Paterek Scale: full size
Materid: T-6 Aluminum or 1020 Steel Tolerances: -+1/6 4"- fractional, .t.003"- decimal
DI RECTI ONS FOR I MPLEMENTI NG THE GENERI C PATEREK CATALOG
1. Anyone who pur chases t hi s cat al og at f ul l whol esal e pr i ce i s gi ven
per mi ssi on t o make t he necessar y al t er at i ons wi t hi n and r epr oduce t hei r
own per sonal i zed ver si on i n any quant i t y t hey deemnecessar y.
2. Af t er each r epai r , br aze- on, or pai nt i ng pr ocedur e t her e i s a number
i n par ent heses. Thi s number i s an est i mat i on of r oughl y how l ong t he
i t emshoul d t ake a bui l der i n hour s. For expampl e: a ( . 8) woul d mean
ei ght t ent hs of an hour t o do t hat par t i cul ar j ob. That number i n
par ent heses can be mul t i pl i ed by t he hour l y r at e t he bui l der char ges.
For exampl e: i f t he bui l der char ges $20. 00 per hour ( not an unr eal i st i c
f i gur e) , mul t i pl y t he ( . 8) above by $20. 00. The answer i s $16. 00.
That woul d be t he l abor char ge f or an i t emt aki ng ei ght t ent hs of an
hour at $20. 00 per hour . Go t hr ough t he whol e cat al ogue and f i gur e out
t he cor r ect amount s t o wr i t e i n t he bl anks. HI NT: Tr y t o t ype i n t he
number s or use t r ansf er l et t er i ng t o cr eat e a pr of essi onal l ook.
3. Some i t ems wi l l have a second bl ank af t er t he l abor pr i ce. Thi s
second bl ank i s f or cost of mat er i al s. For exampl e: i nst al l i ng a
br azed- on f r ont der ai l l eur woul d have a l abor char ge as wel l as a cost
of mat er i al s char ge f or t he der ai l l eur i t sel f . Onl y some i t ems wi l l
have t hi s second bl ank. Go t hr ough t he whol e cat al og and f i gur e out a
r et ai l pr i ce t o wr i t e i n t he cost of mat er i al s bl anks.
4. Al l l i ne dr awi ngs t hr oughout t he cat al og have had t he geomet r i cal
specs del et ed. Wr i t e i n t he pr ef er r ed specs f or each model bi ke. For
exampl e: wr i t e i n a head t ube angl e of 73 degr ees f or a t our i ng bi ke i f
t hat i s t he angl e t hat you put on t hat model of bi ke.
5. At t he bot t omof t he page of cont ent s i s a space f or your busi ness
car d. Gl ue one of your busi ness car ds i n t hat space. HI NT: A bl ack
and whi t e busi ness car d wi l l l ook t he most pr of essi onal .
6. Wi t h t r ansf er l et t er i ng, l et t er your name on t he f r ont cover .
7. At t he t op of page si x ar e specs f or sever al t aps r eamer s and di es.
Take a bot t l e of "whi t e- out " and bl ank out t he si zes you do not own.
8. Af t er al l of t he necessar y dat a has been ent er ed i nt o t he gener i c
cat al ogue, t ake i t t o your pr i nt er and have as many copi es as necessar y
r un of f .
9. Di spose of t hi s page.
TABLE OF CONTENTS
Br aze- on pr i ce l i st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pai nt i ng pr i ce l i st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fr ame r epai r pr i ces and descr i pt i ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tour i ng f r ameset s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spor t / t our i ng f r ameset s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raci ng f r ameset s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bui l der ' s guar ant ee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Or der i ng i nf or mat i on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fr ameset or der f or m. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component or der f or m
***************************************
* *
* *
* *
* *
gl ue your busi ness car d her e
* *
* *
* *
* *
***************************************
BRAZE- ON PRI CE LI ST
l abor mat er
1. Wat er Bot t l e Mount s
A. Pl ai n . . . . . . . . ( . 25) S S
B
. Scal l oped Di amond St i f f ener s . . . . . . . . . . . . ( . 30) 5. . . . .
C. Pl ai n Di amond St i f f ener s . . . . . . . . . . . . . . . . ( . 30) $. . . . . . $
2. Br azed on Fr ont Der ai l l eur ( i ncl udes Der ai l l eur )
A. Campagnol o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 80) $. . . . .
Shi mano Dur a Ace . . . . . . . . . . . . . . . . . . . . . . . . ( . 70) $. . . . .
3. Shi f t Lever Bosses
A. Campagnol o
( al so f i t s; Si mpl ex S. L. J . . Ri no Sunt our ) ( . 40) $ S
R. Modi f i ed Campagnol o ( f or use of Par cons) . ( . 50)
c
$
C. Shi mano . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 40) . . . . . $ --
4. Cant i l ever Br ake set s ( speci f y r egul ar . t andemor mount ai n use)
Lever s and cabl es not i ncl uded
A. Maf ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 60) 5. . . . .
B
. Di a Compe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 60) $. . . . . . S
C. Shi mano . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 60) 5. . . . . . 5
5. Rear Rack Fi t t i ngs
A. I nt er nal ( usi ng wat er bot t l e boss) . . . ( . 30) $
R. Ext er nal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 25) S. . . . . . 5
6. Low Ri der Mount s ( ol d st yl e) . . . . ( . 40) 5 5
Low Ri der Mount s ( new st yl e) . . . . . . . . . . . . . . . . ( . 75)
5 5
7. Top Tube Cabl e Gui des
A. 2 Cl ose Loops . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 50) 5
B. 2 Di st ant Loops . . . . . . . . . . . . . . . . . . . . . . . . ( . 50)
C. 1 Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 50) 5. . . . . 5
8. Cabl e St op
A. Shi mano . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 20) 5. . . . .
B. Campagnol o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 20) 5. . . . . . 5
C. Spl i t St yl e . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 20) S. . . . . 5
D. Heavy Dut y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 20)
5
9 Pudic Peg - Speci f y br and l engt h, and t ube t o be i nst al l ed on
A. St andar d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( , 25) $
B
. 1/ 4' hal l t o mount Si l ca under t op t ube . ( . 25) $
$
10. Cl amp st op. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( . 20) r 5
11. Chai n Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 20) $$
--
12. Bot t omBr acket Gui des
A. Campagnol o ( t on si de) . . . . . . . . . . . . . . . . . . ( . 50) S. . . . . . 5
B. Shi mano ( t op si de) . . . . . . . . . . . . . . . . . . . . . . ( . 50) 5........... 5
C. Ci nel l i ( t op si de) . . . . . . . . . . . . . . . . . . . . . . ( . 58)
$
D. Under Si de . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 60) $
13. Bar con st ops S
p
eci f y st yl e ( see # ) ( 50) 5
14. Ext r a Eyel et s f or f ender s ( pai r )
. . . . . . . . . . . . ( . 40)
15. Br ake br i dge r ei nf or ci ng sl eeve
A. St andar d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 60) 5. . . . .
5
B
. Al l en Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 60)
15. Spoke Car r i er / Chai nst ay Guar d . . . . . . . . . . . . . .
( . 90) 5
17. Cent er Ful l Hanger
A. Si mpl e Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 75) $
9. Tr i an
g
ul ar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1. 2) $ . $
-
2.-
PAI NTI NG PRI CE LI ST l abor mat er
OVERHAUL FOR PAI NTI NG: Thi s i ncl udes r epacki ng t he bot t om
br acket & head and r emovi ng & r epl aci ng al l component s. ( 3) $ ?
Over haul hubs and dr i ve t r ai n ( addi t i onal char ge) . . . ( 1. 5) $
STRI PPI NG OLD PAI NT: Pai nt i s r emoved wi t h an i ndust r i al
ai r cr af t st r i pper . Sandbl ast i ng i s har sh and can damage
t hi nwal l t ubi ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( 1 t o 2) $. . . . .
REMOVI NG EXTENSI VE SURFACE RUST: I f t her e i s a l ot of
sur f ace r ust wher e t her e ar e bar e spot s i n t he exi st i ng
pai nt j ob, t hi s must be r emoved wi t h a wi r e wheel . ( . 5 t o 1) $
MASKI NG CHROME:
St ays and r ear dr opout s
( 1) $
For k bl ades. ( 1) $
Head l ugs
( 1) $
For k cr own ( 1) $
CLEAR COAT: The onl y t i me a cl ear coat i s appl i ed i s t o
pr ot ect decal s or when i t i s speci f i cal l y asked f or . . . ( 1) $ $
SI NGLE COLOR PAI NT J OB: Al l pai nt j obs wi l l be done wi t h
aut omot i ve qual i t y pai nt s. Make sur e a car d or pi ece of
maski ng t ape i s f i r ml y at t ached t o t he f r ame whi ch has t he
f r ame ser i al number , new col or name, and col or number on i t .
Al so i ncl udes met al pr ep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( 3) $. . . . . $
TWO TONE PAI NT J OB: Wi t h magi c mar ker , mar k exact l y wher e
t he cont r ast i ng col or bands wi l l be. Wr i t e ser i al number ,
col or names, - and col or number s on a car d or pi ece of maski ng
t ape and at t ach i t t o t he f r ame. BE VERY CLEAR AS TO WHICH
I S THE BASE COLOR AND WHI CH I S THE CONTRASTING COLOR!! Also
i ncl udes necessar y maski ng and cl ear coat ( 4 5) $ $
DECAL WORK: Decal wor k i s done on an i ndi vi dual basi s. Al l
r equest s f or decal s wi l l be gi ven an est i mat e at $ per
hour bef or e begi nni ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 4-
FRAME REPAI R PRI CES
THESE PRI CES ARE FOR A FULLY STRI PPED FRAMESET.
Bot t ombr acket t aps on hand: Br i t i sh I t al i an Fr ench Swi ss
St eer i ng col umn di es on hand: Br i t i sh I t al i an Fr ench
Head t ube r eamer s on hand: 30. 2mm30. 0mm
Cr own r ace cut t er s on hand: 26. 4mm27. 2mm
l abor mat er
BOTTOM BRACKET
Cl ean out or st r ai ght en out t hr eads . . . . . . . . . . . . . . . . . . . . ( . 25) $
Face mi l l i ng ( l i ght cut ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 25) $
Face mi l l i ng f r om70mm t o 68mm( heavy cut ) . . . . . . . . . . . . ( . 50) $
Fi l l damaged t hr eads wi t h br ass and cut new
t hr eads t o t he or i gi nal t hr ead specs ( 1 0) S
Reamand r et ap t o I t al i an specs . . . . . . . . . . . . . . . . . . . . . . . . ( . 50) $
Repai r st r i pped I t al i an bot t ombr acket
shel l t o accept Br i t i sh or Fr ench cups ( 2 0) $ $
Rei nser t and r ebr aze an exi st i ng f r ame t ube whi ch
has pul l ed out of t he bot t ombr acket shel l . . . . . . ( . 75) $
HEAD
J ack out f r ame whi ch i s bent f r oma head- on col l i si on
( Ther e may be r i ppl es l ef t af t er t hi s. ) ( 40) $
Mi l l and r eamt op and bot t omof head t ube
( Speci f y pr ess f i t di mensi ons desi r ed. )
(
25) $
Remove head t ube t wi st - - t o put head t ube
and seat t ube i n t he same pl ane . . . . . . . . . . . . . . ( . 50 t o 1. 5) $
FORK
Ream22mmFr ench st eer i ng col umn t o 22. 2mmBr i t i sh si ze. . ( . 25) $
St r ai ght en bl ades t o desi r ed r ake ( 25) $
St r ai ght en st eer i ng col umn whi ch i s bent
at t he si t e of t he cr own r ace or above ( 20) $
Al i gn t i ps ( 20) $
Reat t ach dr opout ( send ol d dr opout wi t h f or k) ( 80) $
Repl ace dr opout s . . . . . . . . . . . . . . . . . . . . . . . . . . 20. 00 ( 2. 0) $
Repl ace bl ades: ( speci f y br i t i sh or cont i nent al ) . . . . . ( 2- 5) $
Mi l l f or k cr own r ace seat . ( Speci f y 26. 4mmor 27. 2mm) . . . ( . 25) $
Tap st eer i ng col umn t o f i t smal l er f r ame
Fi r st cent i met er ( , 25) $
Each addi t i onal cm ( 10) $
Fi l l damaged t hr eads wi t h br ass
and r et ap t o ol d t hr ead specs ( 75) $
- 6-
FRAME REPAI R PRI CES cont .
REAR TRI ANGLE l abor mat er
Repl ace dr opout s ( Speci f y br and)
Each ( 2 0) $
Pai r ( 3 0) $
Repl ace chai nst ays ( Speci f y br and)
I ncl udes br i dge and cabl e st op
Each ( 2 5) $
Pai r ( 4 0) $
Repl ace seat st ays ( Speci f y br and)
I ncl udes br ake br i dge & chai nhanger
Each ( 2 5) $
Pai r
( 4 0) $
Repl ace or r el ocat e br ake br i dge
St andar d br i dge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( l . 25) $_ _ _ _ _ $
Br i dge wi t h st i f f ener s and r ei nf or cer . . . . . . . . . . . . . ( l . 50) $_ _ _ _ _
St r ai ght en seat st ay wi t h no ki nk . . . . . . . . . . . . . . . . . . . . ( . 25) $. . . .
St r ai ght en seat st ay and f i l l & smoot h out ki nk . . . . . ( 1. 00) $
Fi l l der ai l l eur hanger t hr eads wi t h br ass and r et ap. . . ( . 50) $- - - - -
Modi f y Si mpl ex dr opout t o accommodat e Campy der ai l l eur . ( . 50) $
Cl ean out chai n adj ust er t hr eads . . . . . . . . . . . . . . . . . . . . ( . 25) $- - - - -
Al i gn t i ps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 20) S
Al i gn der ai l l eur hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ( . 20) $-
Real i gn r ear t r i angl e t o be i n t he
same pl ane as t he f r ont t r i angl e . . . . . . . . . . . ( . 50 t o 1. 50) $
Open r ear t r i angl e t o accomodat e 6 speed
Col d bend ( not hi ghl y r ecommended) . . . . . . . . . . . . . . . . ( . 25) $
I nst al l l onger br ake br i dge- - see above.
FRONT TRI ANGLE
Reamseat t ube f or an easy sl i de f i t wi t h seat
post . ( Send seat post t hat wi l l be used ) . . . . . . . . . . ( . 25) $
Repl ace r ui ned seat post bi nder bol t ( 1 0) $
Spl i ce a cr acked f r ame t ube back t oget her ( 1 0) $ $
Repl ace head t ube ( 3 $- - - -
Repl ace down t ube ( 3 $- - - -
Repl ace t op t ube ( 3 5) $ $- - - -
Repl ace seat t ube ( 3 5) $
Repl ace bot t ombr acket shel l . . . . . . . . . . . . . . . . . . ( 4. 0 t o 6. 0) 5
Repl ace t op t ube, head t ube, and down t ube . . ( 8. 0 or mor e) $
****************************************
* *
* WARNI NG: SOME OF THE REPAI RS LI STED *
* I N THI S CATALOG MAY NULLI FY THE *
* FACTORY WARRANTY. DI SCUSS THI S WI TH *
* A DEALER OR DI STRI BUTOR I F THERE *
* ARE ANY QUESTI ONS I N THI S MATTER. *
* *
****************************************
- 7-
FRAME REPAI R PRI CES cont .
l abor mat er
DRESSI NG A FRAME
Si nce many new f act or y f r ames ar e not cl eaned up ver y wel l
at t he f act or y, t he deal er must see t o i t t hat t he bot t om
br acket i s t apped and f aced, t he head t ube i s mi l l ed and
r eamed, t he f or k cr own i s mi l l ed, t he seat t ube i s r eamed
f or a pr oper f i t , t he t i ps ar e al i gned, and al l smal l
t hr eaded hol es ar e cl eaned out . ( Thi s shoul d al so be done
af t er pai nt i ng) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
( 1. 5) $ $
COSMETI C REPAI RS
Any "body wor k" t o he done on f r ames wi l l be gi ven a wr i t t en
est i mat e and sent t o t he cust omer f or appr oval bef or e
st ar t i ng.
Al l bur ned pai nt on f r ame r epai r s wi l l be f eat her ed out and
cover ed wi t h pr i mer . A compl et e r epai nt i s advi sed.
Heat ed chr ome wi l l di scol or and wi l l not be r echr omed unl ess
r equest ed. Est i mat e on pr i ce and t i me wi l l al so be gi ven.
- 8-
CUSTOM FRAMES
These f r ames ar e each i ndi vi dual l y desi gned and hand
bui l t one at a t i me. No t wo f r ames ar e t he same unl ess
or der ed t hat way by a cust omer . They ar e bui l t t ot al l y
t o t he buyer ' s speci f i cat i ons and r equest s. Ever y l ug,
dr opout , and bot t ombr acket shel l i s f i l ed and sanded
t o r emove unsi ght l y bl emi shes. Each j oi nt i s br azed
and i nspect ed f or al i gnment and wor kmanshi p bef or e
cont i nui ng. A super i or aut omot i ve qual i t y f i ni sh i s
appl i ed t o f ur t her enhance t he f i ne wor kmanshi p al r eady
i nher ent i n t he f r ame. As a f ur t her ser vi ce t o t he
cust omer , t he f r ameset i s car ef ul l y "dr essed" t o al l ow
t he component s t o be i nst al l ed wi t hout pr obl ems.
Level - 1 ( TOURI NG) These ar e bui l t f or t he begi nni ng or
l i ght dut y t our i st . Doubl e but t ed t ubi ng,
st amped bot t ombr acket shel l , st amped
dr opout s, st amped l ugs, and cast cr own come
st ock on t hi s model . For t our i ng t hese f r ames
have a l ow bot t ombr acket , l ong chai nst ays.
shal l ow head t ube an
g
l e wi t h mat chi ng r ake and
cl ear ance f or f ender s. Br aze- ons i ncl ude one
wat er bot t l e. bot t ombr acket
g
ui des t op t ube
gui des. chai nst ay cabl e st op, chai nhanger ,
r ear r ack mount s. and ext r a eyel et s f or
mount i ng f ender s. The f i ni sh i s an
aut omot i ve
q
ual i t y f i ni sh wi t h myl ar decal s.
Pr i ce S
- 11-
LEVEL- 1 ( SPORT/ TOURI NG) These ar e bui l t f or t he
begi nni ng spor t r i der who l i kes t o t our at a
f ast pace wi t h a l i ght l oad as wel l as dabbl e
i n a l i t t l e amat eur r aci ng. Doubl e hut t ed
t ubi ng, st amped bot t ombr acket shel l , st amped
dr opout s, st amped l ugs, and cast cr own come
st ock on t hi s model . For spor t / t our i ng t hese
f r ames mai nt ai n a happy medi umi n head t ube
angl e, r ake, bot t ombr acket dr op, and
chai nst ay l en
g
t h. Br aze- ons i ncl ude one wat er
bot t l e
: bot t ombr acket gui des, t op t ube
gui des, chai nst ay cabl e st op and chai nhanger .
The f i ni sh i s an aut omot i ve f i ni sh wi t h myl ar
decal s. pr i ce $
- 12-
LEVEL- 1 ( RACI NG) These ar e bui l t f or t he begi nni ng
r acer who i s ent er i ng ci t i zen r aces or r aci ng
cat egor y 4. Doubl e but t ed t ubi n
g
, st amped
bot t om br acket shel l , st amped dr opout s,
st amped l ugs and cast cr own come st ock on t hi s
model . For r aci ng t hese f r ames have a hi gh
bot t ombr acket , shor t chai nst ays, st eep head
t ube angl e wi t h mat chi ng r ake and mi ni mum
cl ear ances. Br aze- ons i ncl ude one wat er
bot t l e, bot t ombr acket gui des, t op t ube
gui des, chai nst ay cabl e st op, and chai nhanger .
Eyel et s ar e r emoved. The f i ni sh i s an
aut omot i ve f i ni sh wi t h myl ar decal s.
pr i ce
- 13- -
LEVEL- 2 ( TOURI NG) These ar e bui l t f or t he mor e
exper i enced t our i st who t akes ext ended t r i ps
wi t h a l ot of gear . Doubl e but t ed t ubi ng,
cast bot t ombr acket shel l , cast cr own, cast
l ugs, and f or ged dr opout s come st ock on t hi s
model . For t our i ng t hese f r ames have a l ow
bot t ombr acket , l ong chai nst ays, shal l ow head
t ube wi t h mat chi ng r ake, and cl ear ance f or
f ender s. Br aze- ons i ncl ude t wo wat er bot t l es,
bot t ombr acket gui des, t op t ube gui des,
chai nst ay cabl e st op, chai nhanger , r ear r ack
mount s, ext r a eyel et s f or f ender s, spoke
car r i er , l owr i der br aze- ons, pump peg,
modi f i ed l ever bosses, cant i l ever s, and
cent er - pul l hanger . The f i ni sh i s a
pol yur et hane enamel wi t h dr y t r ansf er decal s
and a f i nal coat of cl ear on t op.
pr i ce $
- - 14-
LEVEL- 2 ( SPORT/ TOURI NG) These ar e bui l t f or t he spor t
r i der t hat l i kes t o t our f ast wi t h a char ge
car d and t r avel er ' s checks yet dabbl e i n
amat eur r aci ng. Doubl e but t ed t ubi ng ( SL
avai l abl e on r equest ) , cast bot t ombr acket
shel l , cast cr own, cast l ugs, and f or ged
dr opout s come st ock on t hi s model . For
spor t / t our i ng t hese f r ames mai nt ai n a happy
medi umi n head t ube angl e, r ake, bot t om
br acket dr op, and chai nst ay l engt h. Br aze- ons
i ncl ude t wo wat er bot t l es, bot t ombr acket
gui des, t op t ube gui des, chai nst ay cabl e st op,
l ever bosses, pump
p
eg and al i en st yl e br ake
br i dge ( Br azed- on f r ont der ai l l eur i s
opt i onal ) . The f i ni sh i s a pol yur et hane
enamel wi t h dr y t r ansf er decal s and a cl ear
coat on t o
p
. pr i ce $
- - 15-
LEVEL- 2 ( RA
C
I NG) These ar e bui l t f or t he ser i ous
r acer who t r ai ns on a r egul ar basi s and
at t ends a number of r aces t hr oughout t he
season. Doubl e but t ed t ubi ng ( SL avai l abl e on
r equest ) , cast bot t ombr acket shel l , cast
cr own, cast l ugs, and f or ged dr opout s come
st ock on t hi s model . r or r aci ng t hese f r ames
have a hi gh bot t ombr acket , shor t chai nst ays,
st eep head angl e wi t h mat chi ng r ake, and
mi ni mumcl ear ances. Br aze- ons i ncl ude t wo
wat er bot t l es, bot t ombr acket gui des, t op t ube
gui des, chai nst ay cabl e st op, l ever bosses,
pump peg, and al i en st yl e br ake br i dge
( br azed- on f r ont der ai l l eur i s opt i onal ) . The
f i ni sh i s a pol yur et hane enamel wi t h dr y
t r ansf er decal s and a cl ear coat on t op.
pr i ce $
- 16-
ADDI TI ONAL BRAZE- ONS Br aze- ons can be added or
subt r act ed f r omany f r ameset or der ed.
See t he br aze- - on pr i ce l i st i n t he f r ont
of t he cat al ogue.
For ver y t al l r i der s. t he Reynol ds Tal l set " can be
bui l t as bi g as 76cm. Thi s adds $50. 00 t o t he cost of
t he f r ame.
For r i der s bet ween 160 and 195 pounds who want t o r i de
SL, t he downt ube and chai nst ays can be r epl aced wi t h
st andar d 531 mat er i al . Thi s adds $35. 00 t o t he cost of
t he f r ame.
FRAMEBUI LDER' S GUARANTEE
Al l f r ames l i st ed her ei n ar e guar ant eed agai nst any def ect s
i n mat er i al s and wor kmanshi p. I n case of a war r ant y
pr obl em, t he f r ame wi l l be r epai r ed or r epl aced at no
char ge. I n t he event any ot her f r amebui l der al t er s or
r epai r s t he f r ame i n any way. t he war r ant y wi l l be
voi ded. Due t o t he f act t hat r i der wei ght and si ze i s
consi der ed i n t he
p
r oduct i on of al l t hese f r ames, t he
war r ant y ends upon sal e of t he f r ame t o a second owner .
I n t he event any non- st andar d f r ame st yl e i s r equest ed
by a cust omer , a condi t i onal war r ant y wi l l be wr i t t en
on t he sal es r ecei pt .
ORDERI NG I NFORMATI ON
I f or der i ng a cust omf r ameset pl ease f i l l out t he
f r ameset or der f or mpayi ng par t i cul ar at t ent i on t o t he
f ol l owi ng i t ems:
HEI GHT: I n met r i c i f
p
ossi bl e. Bar ef oot onl y.
WEI GHT: Thi s i nf or mat i on i s needed t o t el l whi ch
t ube set may he best f or you.
I NSEAM: Cr ot ch t o f l oor bar ef oot ed.
ARM LENGTH: Shoul der t o wr i st .
CUBI T LENGTH: Thi s measur ement i s t aken by bendi ng
your el bow and measur i ng f r omt he t i p of t he el bow
t o t he t i p of your mi ddl e f i nger .
FRAME TYPE: Raci ng, Tour i ng
:
Spor t / Tour i ng,
( I f you or der a r aci ng f r ame, you may want
t o speci f y i f i t ' s t o be used f or cr i t er i ums. t i me
t r i al s, or gener al r oad r aci ng. )
GEOMETRY SPECS: Seat t ube l engt h i s t he onl y one
t hat f eedback i s r eal l y needed f r omyou.
BRAZE- ONS: Check any addi t i onal br azed on equi pment
t hat you want i f i t ' s not i ncl uded on t he model of
bi ke you want .
MATERI ALS SPECS: You shoul d not have t o wr i t e
anyt hi ng her e unl ess you ar e or der i ng somet hi ng
t hat i s out of t he or di nar y.
NOTES: Wr i t e down t he model f r ame you ar e or der i ng.
e. g. LEVEL 1 LEVEL 2 et c.
SHI PPI NG: I ncl ude $20. 00 f or shi ppi ng and handl i ng.
PAYMENT: Hal f down and hal f on del i ver y.
COLORS AND SPECI AL VARI ATI ONS: An aut omot i ve pai nt col or
char t can be or der ed t o assi st i n
choosi ng t he r i ght col or .
I f i nt er est ed i n
any var i at i ons i n seat cl ust er . br i dges, l ugs
dr opout s, et c. Check THE PATEREK MANUAL f or i deas.
T o d a y ' s Da t e
FR A P E S E T O R DE R FO R M / S P E C S H E E T T a r g e t Da t e
Na m e - NO T E S -
A d d r e s s
P h o n e
H e i g h t We i g h t
I n s e a m A r m Le n g t h
C ub i t Le n g t h
Fr a m e T y pe
G E O M E T R I C S P E C S :
S e a t t ub e l e n g t h
T o p t ub e l e n g t h
Fr o n t c e n t e r
C h a i n s t a y l e n g t h
S e a t t ub e a n g l e
H e a d t ub e a n g l e
Bo t t o m b r a c ke t d r o p
Fo r k r a ke
E s t i m a t e d t r a i l
Br i d g e c l e a r a n c e
C r o wn / t i r e c l e a r a n c e
R e a r h ub wi d t h
T i r e s i ze
BR A ZE - O NS : a d d $ M A T E R I A LS S P E C S :
L. H . BB g ui d e T ub i n g
R . H . BB g ui d e Lug s
C h a i n s t a y s t o p Bo t t o m b r a c ke t
W. B. #1 Fo r k c r o wn
W. B. #2 Dr o p o ut s
W. B. #3 P a i n t
W. B. #4 Br a zi n g M a t e r i a l
T o p t ub e s t o ps
T o p t ub e g ui d e s C O S T O F FR A M E S E T :
Le v e r b o s s e s
Ba r c o n s t o ps Ba s e pr i c e o f f r a m e $
P um p pe g
R e a r r a c k m o un t s E xt r a b r a ze - o n s
Lo w r i d e r m o un t s
S po ke c a r r i e r S pe c i a l r e que s t s
C a n t i l e v e r s
C ut - o ut s S ub t o t a l
H e a d c r e s t
O t h e r
T a x
T o t a l
Do wn pa y m e n t
Br a ze - o n t o t a l
Ba l a n c e Due
C O M P O NE NT S H E E T / O R DE R BLA NK Da t e
E s t . De l i v e r y Da t e
DE S C R I P T I O N E S T I M A T E D P R I C E A C T U A L P R I C E
Dr i v e T r a i n :
C r a n ks
BB
C h a i n r i n g s
P e d a l s
T o e c l i ps
T o e s t r a ps
C h a i n
Fr e e wh e e l
Wh e e l s :
H ub s
S po ke s
R i m s
R i m s t r i ps
T ub e s
T i r e s
S h i f t i n g s y s t e m :
Fr . d e r a i l l e ur
R . d e r a i l l e ur
Le v e r s
C a b l e s
C l a m ps
Br a ke s y s t e m :
R un n i n g g e a r :
H e a d s e t
S e a t po s t
S a d d l e
Ba r s
S t e m
Ba r Wr a p
P l ug s
P i n c h b o l t
A c c e s s o r i e s :
P um p
C a r r i e r
Li g h t s
Bo t t l e r a c k
Bo t t l e
S pe e d o
Lo c k
O t h e r :
Na m e
C o m po n e n t G r o up T o t a l
A d d r e s s
T a x
T o t a l
P h o n e Zi p Do wn P a y m e n t
Bi ke T y pe Ba l a n c e Due
GLOSSARY
Thi s gl ossar y i s composed mai nl y of t er ms associ at ed wi t h
bi cycl e f r amebui l di ng. Ther e ar e many ot her t er ms wi t hi n t hi s
l i st t hat come f r omt he ar eas of met al l ur gy and machi ne shop.
Toget her , t hese ar eas wi l l pr ovi de a l ar ge vocabul ar y of t er ms f or
t he bi cycl e f r amebui l der .
ACME THREAD, A t hr ead f or mchar act er i zed by
bei ng bl unt and t hi ck wi t h t he f aces of
t he t hr ead bei ng at onl y a sl i ght angl e.
Thi s t hr ead f or mi s par t i cul ar l y usef ul i n
handl i ng a l oad whi ch exer t s i t sel f al ong
t he l engt h of t he t hr eaded r od. An ACME
t hr ead may be f ound on some hand oper at ed
f r amebui l der ' s cut t i ng t ool s.
AMERI CAN NATI ONAL THREAD, The t hr eads commonl y
f ound on st ove bol t s i n har dwar e st or e
bi ns. The t hr ead f or mi s a uni f or mone
wi t h 60 degr ee angl es on t he f aces of t he
t hr eads and t he peaks of t he t hr eads
sl i ght l y r ounded. Thi s t hr ead i s
par t i cul ar l y usef ul wher e hi gh pr eci si on
i s not r equi r ed and hi gh vol ume pr oduct i on
i s necessar y.
ANNEAL, To heat a met al , such as st eel , and cool
i t sl owl y. By doi ng t hi s st eel can be
sof t ened f or easi er machi ng. Anneal i ng
al so makes t he met al l ess br i t t l e.
ANODI ZE, An el ect r ol yt i c pr ocess i n whi ch t he
sur f ace of a pi ece of met al f or ms a
pr ot ect i ve coat i ng f or t he met al . I n
pr act i ce, i t amount s t o a t ype of
"cont r ol l ed cor r osi on" whi ch i s usual l y
used on al umi numcomponent s i n t he bi cycl e
i ndust r y. Wi t h sl i ght modi f i cat i ons t o
t he pr ocess, al most any col or t hat i s
desi r ed can be pr oduced.
BEVEL PROTRACTOR, A pr eci si on measur i ng devi se
used t o measur e angl es i n smal l
i ncr ement s. Some ar e equi pped wi t h a
ver ni er scal e whi ch al l ows measur ement s
down t o 5 mi nut es i n accur acy.
12- 1
BORE, A pr ocess used i n machi ne shops t o
enl ar ge a hol e i n a pr eci se manner . I n a
l at he a st abl e bor i ng bar hol di ng a t ool
bi t goes down t he i nsi de of t he hol e whi l e
t he pi ece t ur ns. I n a mi l l a spi nni ng
t ool bi t goes down i nt o t he hol e of a
r i gi dl y hel d pi ece of met al . Bor i ng
guar ant ees t he di amet er , l ocat i on, and
dept h of a hol e t o speci f i ed t ol er ances.
BOSS, Any pr ot r usi on whi ch comes up beyond t he
sur f ace of an obj ect . I n bi cycl e f r ames
t hi s woul d r ef er t o many t ypes of
br aze- ons, ( e. g. , l ever bosses, wat er bot t l e
bosses, chai nhanger boss, et c. )
BOTTOM BRACKET DROP, The di st ance bel ow t he
cent er s of t he axl es t he cent er of t he
cr ank spi ndl e l i es.
BOTTOM BRACKET SET, The set of par t s consi st i ng
of spi ndl e, cups, bear i ngs, l ockr i ng, and
pr ot ect i ng sl eeve whi ch ar e i nser t ed i nt o
t he bot t ombr acket shel l .
BOTTOM BRACKET SHELL, A f i t t i ng t hat can be
st amped, cast , or i n t he case of l ugl ess
bui l di ng, machi ned. I t f or ms t he uni on
bet ween t he seat t ube, down t ube, and
chai n st ays, and pr ovi des a t r ansver sel y
t hr eaded hol e f or i nst al l at i on of t he
bot t ombr acket set .
BRAKE BRI DGE, The cr oss member spanni ng t he
seat st ays j ust above t he r ear wheel . I t .
i s usual l y br azed i n pl ace and pr ovi des a
st abl e mount i ng pl ace f or r ear cal i per
br akes, f ender s, or car r i er s.
BRAZE, A met al j oi ni ng pr ocess i n whi ch par ent
met al s ar e j oi ned by mel t i ng bet ween t hem
an al l oy t hat mel t s at a l ower t emper at ur e
t han t he par ent met al s. The al l oy cement s
t he par ent met al s t oget her wi t hout
dr ast i cal l y al t er i ng t hei r physi cal
char act er i st i cs. Common br azi ng al l oys
ut i l i ze el ement s such as si l ver , br ass,
and ni ckel . Br azi ng r ef er s onl y t o
per f or mi ng t he above pr ocess at 800
degr ees F or hi gher . Synonym: HARD
SOLDERI NG.
BRAZE- ONS, Any cl i p, peg, or boss whi ch i s
at t ached t o t he sur f ace of t he f r ame by
means of t he br azi ng pr ocess.
12- 2
BURR, See wi r e edge.
BUTTED, Any t ype of t ubi ng t hat has a uni f or m
out si de di amet er di mensi on but has abr upt
changes i n t he i nsi de di amet er t hus gi vi ng
t he t ube t hi cker wal l s at t he ends.
BUTTRESS THREAD, An asymmet r i cal t hr ead f or mi n
whi ch one t hr ead f ace comes out f r omt he
shaf t at a r i ght angl e t o t he shaf t . The
opposi ng t hr ead f ace has a ver y gr adual
sl ope. These t hr eads ar e par t i cul ar l y
usef ul when t her e i s a l oad i n one
di r ect i on but not i n t he ot her di r ect i on.
CADMI UM, An el ement somewhat r esembl i ng t i n i n
appear ance. When mel t ed, i t gi ves of f a
yel l owi sh gas whi ch can cause sever e
r espi r at or y di sor der s. Cadmi umshoul d be
consi der ed danger ous and pr oper
vent i l at i on and br eat hi ng appar at us shoul d
be used when wor ki ng wi t h i t . Cadmi umi s
t he el ement t hat gi ves si l ver sol der i t s
excel l ent f l ow char act er i st i cs.
CAMBER, To ar ch sl i ght l y. See f or k r ake.
CARBI DE, A compound of car bon wi t h a met al . Used
i n maki ng cut t i ng t ool bi t s because of i t s
ext r eme har dness. Car bi de bi t s ar e
pr oduced by compr essi ng powder ed car bi de.
Of t en mi xed wi t h t ungst en.
CARBURI ZI NG FLAME, A f l ame used i n Oxy- Acet yl ene
i n whi ch t her e i s mor e acet yl ene t han
oxygen. Char act er i zed by a l onger sof t
bl ue f l ame. Good f or doi ng wor k wher e
oxi dat i on i s a pr obl em.
CASE HARDENI NG, To har den st eel or an al l oy of
st eel on t he out er sur f ace onl y. Done by
a combi nat i on of heat t r eat ment and
addi t i on of car bon.
CAST, To f or ma pi ece of met al i n a mol d whi l e
i t i s i n a l i qui d st at e.
CASTER, The st at e of bei ng out of par al l el as i n
wheel s or , mor e not abl y, dr opout s.
CENTER PUNCH, A har dened met al r od whi ch has a 90
degr ee poi nt gr ound on t he end. I t i s
used f or maki ng a mar k mor e vi si bl e t han
one l ef t by a pr i ck punch. A cent er punch
i s usual l y hi t wi t h subst ant i al f or ce.
12- 3
CHAI N STAYS, The f r ame member s t hat span t he
di st ance bet ween t he bot t ombr acket shel l
and t he dr opout s. Chai n st ays usual l y
have an ext er nal t aper , causi ng a gr adual
decr ease i n out er di amet er f r omone end t o
t he ot her .
CHAI N STAY BRI DGE, The member spanni ng t he
di st ance bet ween t he chai n st ays j ust i n
f r ont of t he r ear t i r e.
CHROMI UM- MOLYBDENUM ALLOY, A st eel al l oy wi t h
t r aces of t he el ement s chr omi umand
mol ybdenum mi xed i n. The r esul t i ng al l oy
i s har der and st i f f er i n physi cal
pr oper t i es. Synonyms: Chr ome- Mol y,
CHRO- MO.
COLD SET, A pr ocess of f or cef ul l y br i ngi ng f r ame
member s i nt o t ol er ance wi t hout t he use of
heat . Can ei t her be done by hand or wi t h
speci f i cal l y desi gned f i xt ur es.
COSMOLI NE, A gr ease used t o pr ot ect met al i t ems
f r omr ust i ng. Of t en appl i ed t o t ube set s
t o ar r est r ust i ng whi l e i n st or age.
COUNTER BORE, 1) To bor e out a cyl i ndr i cal hol e
f or a cer t ai n di st ance so as t o f or ma
f l at bot t omof t he hol e f or r ecei vi ng t he
head of a scr ew. 2) The t ool t hat wi l l do
t he count er bor i ng pr ocess.
COUNTER SI NK, 1) To machi ne out t he t op of a
cyl i ndr i cal hol e so t hat t he t op of t hat
hol e has a cone- shaped conf i gur at i on.
Thi s al l ows a f l at head scr ew t o be dr i ven
i n so t hat t he t op of t hat scr ew i s f l ush.
2) A t ool t hat wi l l do count er si nki ng.
CUBI T, The di st ance f r omone' s el bow t o t he
f i nger t i ps. Can be used as a r ough
i ndi cat or i n det er mi ni ng t he l engt h of t he
handl ebar st em.
DI E, 1) A cut t i ng t ool used t o cut a t hr ead on
t he out si de of a cyl i nder . 2) The f or mi ng
or cut t i ng pi ece hel d i n a pr ess.
DRI LL, To make a hol e i n a pi ece of st ock by use
of a r ot at i ng, hel i cal cut t i ng t ool .
DROPOUTS, The f r ame member t o whi ch t he wheel s
ar e at t ached. OR, The l ocat i on f r omwhi ch
t he wheel s "dr op out " of .
FACE, To cl ean up t he end of a cyl i ndr i cal pi ece
of st ock on a l at he or mi l l i ng machi ne. As
i n f aci ng a bot t ombr acket shel l .
FI LE, 1) A har dened st eel t ool wi t h t eet h f or med
i n i t s f l at t ened sur f ace f or t he pur pose
of met al r emoval . 2) To use a f i l e.
12- 4
FI XTURE, Any speci f i cal l y desi gned pi ece of
equi pment whi ch i s meant t o hol d, bend, or
measur e an i t emdur i ng a manuf act ur i ng
pr ocess. Fi xt ur es ar e usual l y cust om
bui l t or bui l t i n ver y l i mi t ed number s.
FLUORI DES, A chemi cal compound made by t he uni on
of Fl uor i ne and anot her el ement .
Fl uor i des ar e pr esent i n wat er sol ubl e
si l ver sol der f l ux. Fl uor i des ar e ski n
i r r i t ant s and par t i cul ar l y annoyi ng t o t he
mucous membr anes. Gr eat car e shoul d be
t aken so t hat f l uor i des ar e not i nhal ed.
FLUTE, A f ur r ow or gr oove as i n or ni ment at i on on
a col umn. Seat post s ar e of t en f l ut ed.
Some chai n st ays ar e f l ut ed t o make
cl ear ance f or t he t i r e.
FLUX, A subst ance t hat i s appl i ed t o a br aze
j oi nt bef or e br azi ng begi ns t o keep t he
ar ea cl ean and f r ee of oxi dat i on. Fl ux
can come i n past e f or m, powder f or mor
even appl i ed t o t he out er sur f ace of
br azi ng r ods i n har d f or m. I n t he case of
si l ver sol der i ng, f l ux i s al so a
t emper at ur e i ndi cat or . See f l uor i des.
FORK BLADES, The sl i ght l y cur ved f r ame member s
t hat span t he di st ance bet ween t he f or k
cr own and t he f r ont dr opout s. For k bl ades
can come i n r ound, Br i t i sh oval ( nar r ow) ,
or Cont i nent al oval ( f at ) cr oss sect i ons.
FORK CROWN, The f r ame member t hat f or ms a uni on
bet ween t he f or k bl ades and t he st eer i ng
col umn. For k cr owns can come t o f i t
Cont i nent al bl ades, r ound bl ades, or
Br i t i sh bl ades. They can be i nser t ed or
over l appi ng. See t he sect i on on f or k
cr owns i n t he var i at i ons sect i on.
FORK CROWN RACE, The pi ece of t he headset t hat
set s di r ect l y on t he f or k cr own. Commonl y
avai l abl e i n pr ess- f i t di mensi ons of
26. 4mmand 27. 2mm.
FORK CROWN RACE SEAT, The l ocat i on on t he f or k
cr own t hat t he f or k cr own r ace set s on.
I t shoul d be a pr ess- f i t wi t h t he f or k
cr own r ace.
FORK RAKE, The amount of of f set i n t he f or k or a
per pendi cul ar di st ance f r omt he head t ube
cent er l i ne t o t he f r ont axl e cent er l i ne.
FORK SWOOP, A mi sal i gnment r esul t i ng f r omt he
cur vat ur e of t he f or k bl ade not bei ng i n
t he same pl ane as t he oval of t he f or k
bl ade.
12- 5
FRONT CENTER, The di st ance f r omt he cent er of t he
bot t ombr acket t o t he cent er of t he f r ont
axl e.
FRONT TRI ANGLE, That par t of t he f r ame whi ch i s
made up of t he head t ube, down t ube, seat
t ube, and t op t ube. I n act ual i t y, t he
f r ont t r i angl e i s a t r apezoi d.
HEAD TUBE, The f r ame member t hat spans t he
di st ance f r omt he t op t ube t o t he down
t ube. The head t ube usual l y f al l s i n a
nar r ow angl e r ange of 71 t o 75 degr ees of f
hor i zont al .
HEI GHT GAUGE, A pr eci si on i nst r ument used f or
f i ndi ng, t r ansf er r i ng, and mar ki ng hei ght s
whi l e wor ki ng wi t h obj ect s on t he sur f ace
t abl e. A hei ght gauge has no cal i br at ed
mar ki ngs such as a ver ni er hei ght gauge
woul d have.
HI GH CARBON STEEL, A t ype of st eel al l oy i n whi ch
t he amount of car bon added makes t he st eel
ext r emel y har d and i deal f or maki ng
cut t er s t o cut ot her met al s.
HI GH SPEED STEEL, A t ype of st eel al l oy wi t h
t r aces of Chr omi um, Tungst en, or
Mol ybdenum. Hi gh speed st eel makes
excel l ent cut t i ng t ool s and i s somet i mes
pr ef er r ed by machi ni st s over hi gh car bon
st eel .
HONE, Honi ng dr esses t he i nsi de sur f ace of a
cyl i ndr i cal hol e t hr ough t he use of spr i ng
l oaded spi nni ng st ones. Honi ng does not
guar ant ee l ocat i on, di amet er , and dept h of
a hol e as bor i ng does. Onl y smal l amount s
of met al shoul d be r emoved by honi ng.
HYDROCHLORI C ACI D, An aqueous sol ut i on of
Hydr ogen Chl or i de. ( HC1) A ver y st r ong
aci d whi ch can be used i n r ust r emoval and
some cl ean- up oper at i ons. However , i f
used as such, a r ust r et ar di ng t r eat ment
must i mmedi at el y f ol l ow or t he HCl wi l l
cont i nue t o at t ack t he met al f or some
t i me. USE ONLY WI TH ADEQUATE VENTI LATI ON!
THE FUMES ARE ABSOLUTELY DEADLY I F
I NHALED! Synonym: Mur i at i c Aci d.
HYDROGEN EMBRI TTLEMENT, A condi t i on i n whi ch
avai l abl e hydr ogen act s upon st eel maki ng
i t l ose st r engt h and t end t o shear mor e
easi l y al ong shear pl anes. The most common
cause of t hi s condi t i on i s due t o pi ckl i ng
and pl at i ng bat hs. Thus, chr ome pl at i ng
can be a si gni f i cant cont r i but i ng f act or
t o hydr ogen embr i t t l ement .
12- 6
I . S. O. I nt er nat i onal St andar ds Or gani zat i on. An
or gani zat i on dedi cat ed t o est abl i shi ng
st andar ds and nor ms i n t he i ndust r i al
wor l d.
J I G, See f i xt ur es.
J . I . S. J apanese I ndust r i al Soci et y. An
or gani zat i on of j apanese i ndust r i es
dedi cat ed t o est abl i shi ng st andar ds and
nor ms i n t he J apanese i ndust r i al
communi t y.
LUGS, St amped or i nvest ment - cast f i t t i ngs t hat
f or ma r ei nf or ci ng sl eeve at t he j oi nt s of
bi cycl e f r ames. Can al so be t hought of as
mi ni at ur e f i xt ur es t hat hol d t he f r ame
member s i n pl ace dur i ng br azi ng. See
var i at i ons sect i on f or mor e i nf or mat i on.
MACHI NE, ( ver b) To r emove met al f r oma pi ece of
st ock. The st ock can be hel d r i gi d whi l e
t he cut t er moves over i t , as i n t he case of
a mi l l i ng machi ne or t he st ock can move
whi l e t he cut t er r emai ns st at i onar y, as i n
a l at he.
MANGANESE- MOLYBDENUM, A st eel al l oy wi t h mi nut e
t r aces of t he el ement s manganese and
mol ybdenummi xed i n. t he r esul t i s a
st i f f er and st r onger al l oy mor e sui t abl e
f or f r amebui l di ng.
METRI C, A measur ement syst emi nvent ed dur i ng t he
Fr ench Revol ut i on t hat i s based on a uni t
cal l ed a met er . I t i s an ent i r el y deci mal
syst emt hat i s ext r emel y easy t o use.
Unl i ke ot her measur i ng syst ems, i t has
t ot al cont i nui t y bet ween vol ume, wei ght ,
and di st ance scal es. The met r i c syst emi s
t he pr ef f er ed measur ement syst emof
sci ent i f i c communi t i es and t echnol ogi cal l y
advanced soci et i es.
MI LL, To r emove met al f r oma pi ece of st ock
by hol di ng t he st ock r i gi d whi l e t he
cut t er head gl i des over t he sur f ace.
Mi l l i ng machi nes can be l ar ge and compl ex
l i ke a ver t i cal or hor i zont al mi l l i ng
machi ne or t hey can be ver y si mpl e such as
a hand oper at ed mi l l i ng t ool . One f or mof
mi l l i ng of t en used i n f r amebui l di ng i s
f ace mi l l i ng. Thi s i s done t o t he bot t om
br acket f aces and t he head t ube f aces t o
make t hempar al l el wi t h each ot her .
12- 7
MI TERI NG, A speci al t ype of cut t i ng t hat i s done
t o al l ow pi eces t o come t oget her at an
angl e as i n t he cor ner s of a pi ct ur e
f r ame. I n f r amebui l di ng t hese mi t er ed
j oi nt s wi l l be mor e saddl e shaped,
al l owi ng t he pi eces t o come t oget her at an
angl e and have one wr ap par t i al l y ar ound
t he ot her . Si mpl e mi t er s i nvol ve cut t i ng
onl y one r adi us i nt o t he mi t er . Compound
mi t er s can i nvol ve 2 or mor e r adi i i n t he
mi t er .
MODULUS OF ELASTI CI TY, El ast i ci t y r ef er s t o a
met al ' s abi l i t y t o snap back t o i t s
or i gi nal di mensi ons af t er bei ng subj ect ed
t o st r esses. The modul us of el ast i ci t y
si mpl y quant i f i es t hi s abi l i t y f or
di f f er ent met al s.
NEUTRAL FLAME, I n Oxy- Acet yl ene wor k a neut r al
f l ame i s one i n whi ch equal amount s of
oxygen and Acet yl ene ar e al l owed t o come
t o t he t or ch t i p f or combust i on. Thi s
t ype of f l ame i s char act er i zed by havi ng a
shor t i nner cone t o t he f l ame. Neut r al
f l ames ar e t he speci f i ed f l ame f or many
appl i cat i ons.
OXI DI ZI NG FLAME, I n Oxy- Acet yl ene wor k an
oxi di zi ng f l ame i s one t hat has mor e
Oxygen t han Acet yl ene goi ng t o t he t or ch
t i p f or combust i on. Thi s f l ame t ype i s
char act er i zed by a ver y smal l and br i ght
cone, as wel l as a hi ssi ng noi se. The
maj or use f or t hi s t ype of f l ame i s f or
cut t i ng pur poses whi l e usi ng a speci al
cut t i ng t i p.
PAI NTI NG, The pr ocess of appl yi ng a pr ot ect ve
sur f ace of l acqueur , enamel or l at ex
t o an ot her wi se unpr ot ect ed sur f ace.
Appl i cat i on can be done by br ushi ng,
di ppi ng, spr ayi ng, or el ect r ost at i cs.
Spr ayi ng of l acqueur s and enamel s i s most
of t en used by t he cust omf r amebui l der .
PHOSPHORI C ACI D, Any one of t he t hr ee oxygen
aci ds of phosphor ous. Used t o r emove and
ar r est i r on oxi de ( r ust ) . Al so usef ul i n
pr epar i ng st eel sur f aces t o accept pai nt .
Use onl y i n wel l vent i l at ed ar eas. DO NOT
LET PHOSPHORI C ACI D COME I N CONTACT WI TH
ANY BODY TI SSUES; PARTI CULARLY OPEN SORES,
SCABS, OR MUCOUS MEMBRANES!
12- 8
PLAI N GAUGE, A t ype of t ubi ng t hat has a
const ant wal l t hi ckness t hr oughout .
PI LOT HOLE, A smal l di amet er hol e t hat i s dr i l l ed
bef or e t he desi r ed di amet er hol e i s
dr i l l ed. When goi ng t o a l ar ge hol e
di amet er , sever al pi l ot hol es shoul d be
dr i l l ed i n t he same l ocat i on and each a
f ew st eps l ar ger t han t he l ast . Thi s
l essens t he wor k l oad t hat each successi ve
dr i l l bi t must handl e.
PLATI NG, Put t i ng a t hi n l ayer of met al over t he
sur f ace of anot her met al or even non- met al
pi ece t hr ough t he pr ocess of el ect r ol ysi s.
Pl at i ng can be done wi t h a var i et y of
met al s such as gol d, si l ver , ni ckel ,
chr ome, and br ass. I t can be done f or a
var i et y of r easons, most not abl y f or r ust
pr ot ect i on and decor at i on on bi cycl e
f r ames.
PREHEAT, The per i od of t i me t hat i t t akes t o heat
up a br aze j oi nt t o t he cor r ect
t emper at ur e f or br azi ng t o begi n.
PRESS FI T, A pr eci si on f i t bet ween t wo machi ned
pi eces t hat i s so t i ght t hat ext r eme
pr essur e i s necessar y t o put t he t wo
pi eces t oget her .
PRI CK PUNCH, A har dened met al r od t hat has a 60
degr ee poi nt gr ound on one end. I t i s
used f or maki ng a mar k mor e vi si bl e t han
scr i be mar ks. A pr i ck punch i s onl y hi t
l i ght l y wi t h a hammer .
REAM, To enl ar ge a hol e by usi ng a f l ut ed cut t er
cal l ed a r eamer . Reami ng guar ant ees t he
si ze of a hol e but not i t s l ocat i on or
dept h. Reami ng can be done under power on
a l at he or a mi l l . I t can al so be done by
hand as i n r eami ng a head t ube wi t h t he
cor r ect t ool f r omt he mechani cs t ool case.
REAR TRI ANGLE, That par t of t he bi cycl e f r ame
consi st i ng of t he seat st ays, chai n
st ays, dr opout s, and br i dges.
SAND, To r emove met al i n mi nut e amount s f r oma
pi ece of st ock by r ubbi ng wi t h a si l i con-
car bi de or al umi num- oxi de i mpr egnat ed
pi ece of paper or cl ot h.
SCRI BE, 1) To l ay out mar ks or l i nes t hat show
what f i nal di mensi ons wi l l be or wher e
hol es or ot her modi f i cat i ons wi l l be. To
make scr i be mar ks mor e vi si bl e, l ayout dye
i s br ushed on t he sur f ace bef or e t he mar ks
ar e made. 2) The name of t he t ool used t o
scr i be l i nes.
12- 9
SEAT CLUSTER, That par t of t he f r ame wher e t he
t op t ube, seat t ube, and seat st ays meet .
SEAT STAYS, The f r ame member s t hat span t he
di st ance f r omt he seat cl ust er t o t he r ear
dr opout s.
SEAT TUBE, The f r ame member t hat spans t he
di st ance f r omt he seat cl ust er t o t he
bot t ombr acket . Al so, t he t ube i n t he
f r ame t hat most peopl e wi l l equat e i t s
l engt h wi t h t he act ual si ze of t he bi ke.
SHARP V THREAD, A t heor et i cal t hr ead f or m. Al l
Nat i onal , Whi t wor t h, and Met r i c t hr eads
ar e f l at t ened or r ounded at t he t op and
bot t omof t he t hr eads. The shar p V t hr ead
i s not i n t heor y. However , such a t hr ead
woul d have qui t e r agged edges af t er bei ng
cut and woul d need t o have t hemr ounded.
SHEAR STRENGTH, The amount of r esi st ance
encount er ed when t r yi ng t o shave of f a
pi ece of met al such as a r od. The pr oper
set - up f or t est i ng shear st r engt h i s t o
bol t or r i vet t wo pl at es t oget her ver y
t i ght l y and t hen sl i de t he pl at es apar t
whi ch wi l l shear of f t he bol t or r i vet . A
pr oper l y done, si l ver br azed, l ugged j oi nt
has t r emendous shear st r engt h. I f done
wi t h t oo much cl ear ance, such a j oi nt has
gr eat l y di mi ni shed shear st r engt h.
SI NGLE POI NT, A t er mused t o descr i be t he met hod
i n whi ch t hr eads ar e cut on a l at he or a
mi l l usi ng a speci al si ngl e poi nt i ng head.
Unl i ke a hand- hel d di e and di e- st ock whi ch
uses a cut t er wi t h sever al f l ut es, t he
si ngl e poi nt set up cut s t hr eads wi t h onl y
one t ool bi t t hat has onl y one poi nt
cut t i ng t he t hr ead. I n ef f ect , i t ' s
al most l i ke a needl e movi ng al ong t he
gr oove on a phonogr aph r ecor d. Si ngl e
poi nt i ng by a ski l l ed t echni ci an pr oduces
t he most pr eci si on t hr eads of any met hod.
SLUGS, See Topeye.
SOLDER, A met al j oi ni ng pr ocess i n whi ch par ent
met al s ar e j oi ned by mel t i ng bet ween t hem
an al l oy t hat mel t s at a l ower t emper at ur e
t han t he par ent met al s. The al l oy cement s
t he par ent met al s t oget her wi t hout
dr ast i cal l y al t er i ng t hei r physi cal
char act er i st i cs. The most common
sol der i ng al l oys ar e made of t i n and l ead.
Sol der i ng r ef er s onl y t o per f or mi ng t he
pr ocess bel ow 800 degr ees F. Synonym: sof t
sol der i ng.
12- 10
SPLI NE, 1) A f l at , r ect angul ar pi ece of met al
f i t t i ng i nt o a gr oove or sl ot bet ween
par t s as i n a hub and axl e. Synonym: axl e
key. 2) One of t he l engt hwi se gr ooves on
a spi ndl e t hat has such a set of gr ooves
on t he end so t hat anot her pi ece wi t h a
mat chi ng set of gr ooves wi l l not t ur n on
t hat spi ndl e. Si mi l ar t o f l ut es.
SQUARE, 1) A f our - si ded pol ygon wi t h al l equal
si des and equal angl es. 2) A condi t i on i n
whi ch t wo l i nes or pl anes meet each ot her
at 90- degr ee angl es. 3) A t ool used f or
measur i ng t o see i f t wo l i nes or pl anes
meet at 90- degr ees t o each ot her .
SQUARE THREAD, Thi s i s a t hr ead f or mchar act er -
i zed by havi ng t he f aces of t he t hr ead at
r i ght angl es t o t he l engt h of t he t hr eaded
shaf t . Thi s t hr ead i s par t i cul ar l y usef ul
when t her e i s a l oad al ong t he l engt h of
t he t hr eaded shaf t i n ei t her or bot h
di r ect i ons.
STAMP, 1) To punch a speci f i cal l y cont our ed pi ece
of met al out of a l ar ger sheet of t hat
met al wi t h a cut t i ng di e and a pr ess.
2) To For ma f l at pi ece of met al i nt o a
t hr ee di mensi onal f or mwi t h a f or mi ng di e
and a pr ess.
STEERI NG COLUMN, The t hr eaded por t i on of t he f or k
t hat r i ses near l y ver t i cal l y out of t he
f or k cr own.
STEM, The uni t t hat at t aches t he handl ebar s t o
t he st eer i ng col umn. Col l oq: gooseneck.
STRESS RELI EF, The easi ng of t ensi on bui l t up i n
met al par t s usual l y due t o heat di st or t i on
and f or ces i nvol ved i n br azi ng or wel di ng.
St r ess can be r el i eved i n wel ded par t s by
cer t ai n heat t r eat ment s. St r ess can be
r el i eved i n br azed par t s t hr ough col d
wor ki ng or shot peani ng.
STRESS RELI EF HOLE, A hol e dr i l l ed at t he end of
a sl ot such as t he seat post bi nder sl ot .
Such a hol e spr eads t he st r esses out over
a l ar ger ar ea and l essens t he chance of a
cr ack f r omdevel opi ng f r omt he base of
t hat sl ot .
STI FFENERS, Pi eces br azed t o a bi cycl e f r ame t o
i ncr ease t he wal l t hi ckness i n a
par t i cul ar l ocat i on. Common pl aces f or
st i f f ener s ar e on t he i nsi de f aces of t he
f or k bl ades, ar ound wat er bot t l e hol es, or
at t he ends of t he br i dges. Synonym: t angs
12- 11
SURFACE PLATE, Any bench t op or t abl e t op t hat i s
made of st eel , mar bl e, or gr ani t e and
gr ound t o a pr eci si on f l at ness. Sur f ace
pl at es can be al most any si ze f r om12"
squar e t o sever al f eet acr oss. Uses of
sur f ace pl at es i ncl ude; secur i ng f i xt ur es,
pr eci si on measur i ng and l ocat i ng poi nt s,
l i nes and pl anes on obj ect s. Synonyms:
sur f ace t abl e, t r ue t abl e, t r ue pl at e
SWAGED, 1) To f or mor t o f ashi on especi al l y as
i n i r on or st eel . 2) A t ool used by
bl acksmi t hs f or st ampi ng or mol di ng heat ed
met al i nt o a desi r ed shape. 3) To shape by
means of a swage. For k bl ades, chai n
st ays, and seat st ays ar e "swaged" t o
t hei r desi r ed shape.
TANGS, See st i f f ener s.
TAP, 1) To cut a hel i cal gr oove ar ound t he
out si de of a r ound cyl i nder or t he i nsi de
of a hol e wi t h t he i nt ensi on of bei ng abl e
t o scr ew a mat chi ng pi ece t oget her wi t h
i t . 2) The t ool used t o cut t he hel i cal
gr oove i n t he i nsi de of a hol e.
TAPERED, Any obj ect t hat get s uni f or ml y smal l er
f r omi n si ze f r omone end t o t he ot her .
Seat st ays, chai nst ays, and f or k bl ades
t aper f r omone end t o t he ot her . Some
f r ame t ubes t aper i n wal l t hi ckness. Thi s
i s di f f er ent f r ombut t i ng, as but t i ng i s
an abr upt change i n wal l t hi ckness.
Taper i ng i s a gr adual and uni f or mchange.
TENSI LE STRENGTH, The capaci t y of a mat er i al t o
wi t hst and l ongi t udi nal st r ai n or r upt ur e.
Exampl e: The t ensi l e st r engt h of t he r ope
i s put t o t he t est when pl ayi ng Tug- o- war .
I n The U. S. t ensi l e st r engt h i s measur ed
i n pounds per squar e i nch. I n some
count r i es, i t i s measur ed i n Ki l ogr ams per
squar e mi l l i met er . I n t he sci ent i f i c
communi t y, i t i s f el t t hat t he pr oper way
t o measur e i t i s i n Newt ons per squar e
mi l l i met er .
12- 12
TOOL STEEL, Any of a var i et y of ext r emel y har d
al l oys of st eel used pr i mar i l y f or cut t i ng
met al s whi ch ar e sof t er t han t hese t ool
st eel s. Tool st eel s can be made by
al t er i ng t he amount s, pr esence, or absence
of any of t he f ol l owi ng t r ace el ement s;
Car bon, Chr omi um, Tungst en, and
Mol ybdenum. Tool st eel s ar e di vi ded i nt o
6 maj or cat agor i es: 1. Wat er har deni ng,
2. Shock r esi st i ng, 3. Col d wor k, 4. Hot
wor k, 5. Hi gh speed, and 6. Speci al pur pose.
Most of t he cut t er s on hand oper at ed
f r amebui l di ng t ool s ar e hi gh speed t ool
st eel .
TOPEYE , The i nser t ed, pr ef abr i cat ed pi ece t hat i s
br azed i nt o t he t op of t he seat st ays.
Synonym: sl ug.
TOP TUBE, The hor i zont al ( or near hor i zont al )
f r ame member t hat spans t he di st ance
bet ween t he seat cl ust er and t he head
t ube.
TRAI L, The r esul t of mat hemat i cal l y cor r el at i ng
t he t he var i abl es of head t ube angl e, f or k
r ake, and wheel di amet er . See t he sect i on
on f r ame geomet r y f or gr eat er det ai l .
TUNGSTEN, Thi s met al has t he hi ghest known
mel t i ng poi nt ( 6200 deg F or 3427 deg C) .
I t i s of t en combi ned wi t h car bi de i n
maki ng ext r emel y har d cut t i ng t ool s wi t h a
hi gh r esi st ance t o wear . Ot her uses ar e;
l i ght f i l ament s, scr i bes, and GTAW( TI G
wel di ng) st yl uses.
TURN, To f ashi on a pi ece of met al , wood or
pl ast i c i nt o a desi r ed f or mby mount i ng i t
whi l e mount ed i n t he chuck of a l at he and
r emovi ng mat er i al by r ot at i ng t he st ock
agai nst a r i gi dl y mount ed cut t i ng t ool .
V- BLOCK, A squar e pi ece of met al wi t h a V shaped
gr oove cut i nt o one or mor e si des. I t can
be used t o hol d and/ or secur e cyl i ndr i cal
obj ect s i n r el at i on t o a sur f ace pl at e.
VENT HOLE, Any hol e dr i l l ed i nt o a bi cycl e f r ame
t o al l ow expandi ng gases t o escape saf el y
dur i ng t he br azi ng pr ocess. Synonym: Ai r
expansi on hol e.
VERNI ER, A scal e of t en f ound on pr eci si on t ool s
t o gai n a f i ner degr ee of accur acy.
Ver ni er s can be f ound on cal i per s,
mi cr omet er s, pr ot r act or s, and hei ght
gauges.
12- 13
WELD, To j oi n t wo par ent met al s i nt o one pi ece
by mel t i ng t hemt oget her . Unl i ke br azi ng,
anot her met al i s not used t o bond t he
par ent met al s. I n wel di ng, a f i l l er r od
of t he same mat er i al as t he par ent met al s
i s used t o f i l l gaps and depr essi ons al ong
t he wel d seam. Wel di ng can be done i n a
var i et y of ways, such as; oxy- acet el yne
gas, pr opane gas, Ar c ( somet i mes cal l ed
st i ck wel di ng) , GTAW( somet i mes cal l ed TI G
wel di ng) , GMAW( somet i mes cal l ed MI G
wel di ng) , and Resi st ance wel di ng
( somet i mes cal l ed spot wel di ng) . Most
wel di ng pr ocesses ar e some var i at i on of
t he pr ecedi ng met hods.
WHEEL BASE, The di st ance f r omt he cent er poi nt of
t he f r ont axl e t o t he cent er poi nt of t he
r ear axl e.
WHI TWORTH THREAD, A t hr ead f or mused qui t e
ext ensi vel y i n Gr eat Br i t ai n pr i or t o t he
Second Wor l d War . I t i s char act er i zed by
havi ng t hr ead f aces t hat sl ope at an angl e
of 55 degr ees. The t ops of t he t hr eads
ar e r ounded. Use of Whi t wor t h t hr eads has
gr eat l y di mi ni shed over t he l ast f ew
decades.
WI RE EDGE, A r agged edge al ong a f r eshl y gr ound
or machi ned pi ece of st ock. A wi r e edge
shoul d be r emoved by honi ng. Synonym:
bur r .
WORK HARDEN, To i ncr ease t he har dness of a met al
by by f i l i ng, machi ni ng, bendi ng, or
poundi ng t he met al . Many met al s ar e
speci al l y al l oyed f or t hei r pr oper t y of
bei ng abl e t o be wor k har dened. Shot
peeni ng i s a cont r ol l ed f or mof wor k
har deni ng whi ch adds a si gni f i cant amount
of st r engt h t o t he or i gi nal met al . Thi s
can even r est or e st r engt h l ost t hr ough t he
br ass br azi ng pr ocess. Synonym: col d
wor ki ng
WORM THREAD, A t hr ead f or mt hat i s ver y si mi l ar
t o t he Acme t hr ead. The onl y r eal
di f f er ence i s t hat t he wor mt hr ead has
hi gher peaks on t he t hr eads. See: Acme
Thr ead.
YI ELD STRENGTH, The poi nt at whi ch a met al
act ual l y gi ves i n and begi ns t o def or m.
I n t ensi l e t est s, yi el d st r engt h i s t he
poi nt at whi ch t he met al st ar t s t o st r et ch
but bef or e i n br eaks.
12- 14
I NDEX
Thi s i ndex has been wr i t t en t o pul l al l t he PATEREK mat er i al
t oget her . Af t er t he PATEREK SUPPLEMENT i s cl i pped i nt o t he
PATEREK MANUAL- t hi s i ndex wi l l gi ve l ocat i ons of subj ect s i n
bot h books. When t he l et t er s YP appear af t er an ent r y, t he
i nf or mat i on wi l l be f ound i n t he yel l ow pages at t he end of THE
PATEREK MANUAL. When t he wor d gener al i s used i n an ent r y, i t
i ndi cat es gener al i nf or mat i on i s gi ven on t he subj ect .
AI R COMPRESSOR
gener al 6- - 9 t hr ough 6- 10
i n pai nt i ng 11- 12 t hr ough 11- 13
AI R EXPANSI ON HOLES
bot t omhead l ug
3- 17
f or t op t ube
i n br ake br i dge
3-25, 3-73, 8- 27
3- 47
i n f or k bl ades
i n seat st ays
3-33, 3-84
3-41
down t ube and seat t ube i nt o bot t ombr acket 3-13, 8- 24
ALUMI NUM
oxi de f or mat i on
8- 7, 8- 8
ALUMI NUM LUGLESS J OI NTS
advant ages and di sadvant ages 8- 7
ANDREWHAGUE
f or k j i g
5- 12
f r ame component s YP
f r ame j i g
5- 12
ARM MEASUREMENT
i n f or mul a
1- 5 t hr ough 1- - 6
BELT SANDER
gener al
6- 10
BENOTTO
si zi ng machi ne
YP
BEVEL PROTRACTOR
gener al 6-6 t hr ough 6-7, 9-6
BI LATERAL SYMMETRY
gener al
9- 11
BOTTOM BRACKET
68 and 70mm
2-37
Ci nel l i
2-35
Davi dson
YP
13- 1
BOTTOM BRACKET cont .
di f f er ent nat i onal i t i es 2- 36 t hr ough 2- 37
dr op
f ace mi l l i ng
gui des
3- 15, 3- 50,
1- 13,
3- 66, 3- 105,
2- 11 t hr ough
3- 3
8- 26
2- 12
Haden 2- 36
hei ght 1- 2
Henr y J ames 2- 36
j i g
j i g ( i l l ust r at i on)
3- 13, 3- 65
5- 9
measur i ng dr op 9- 19 t hr ough 9- 20
mi cr omet er
Ot suya- Medal i st
3- 16, 3- 67, 5- 3
YP
RGF 2- 36
st amped and cast 2- 35
Tange YP
t appi ng 3- 15, 3- 50, 3- 66, 3- 105, 8- 26
BOTTOM BRACKET SHELL - LUGLESS
di mensi ons 8- 4
BOTTOM HEAD LUG
ai r expansi on hol e 3- 17
angl e 3- 17 t hr ough 3- 18
BRAKE BRI DGE
f i t t i ng and cut t i ng 3- 45 t hr ough 3- 46
i nst al l at i on of 3- 100
r ei nf or ci ng sl eeve 2- 13 t hr ough 2- 14
st yl es 2- 20 t hr ough 2- 24
BRAZE- ONS
i nst al l at i on of 3- 101 t hr ough 3- 104
pr i ce l i st 4- 2
BRAZI NG
al l oy 3- 12
appl yi ng f l ux 3- 13
bl ades i nt o cr own 3- 34, 3- 90
bot t omhead l ug ont o head t ube 3- 16 t hr ough 3- 17
cl ean and pr ep 3- 11 t hr ough 3- 13
cl ean up 3- 15
down t ube i nt o bot t ombr acket 3- 71 t hr ough 3- 72
down t ube i nt o bot t omhead l ug 3- 18, 3- 69
dr opout s i nt o chai nst ays 3- 37
dr opout s i nt o f or k bl ades 3- 26 t hr ough 3- 27, 3- 83
ext er nal f i l l et s 8- 2
ext er nal - i nt er nal f i l l et s 8- 3
i nt er nal f i l l et s 8- 3
l ower head l ug 3- 68
ni ckel - br onze al l oy 8- 4
ni ckel - si l ver al l oy 8- 4
13- 2
BRAZI NG cont .
pr ocedur e 3- 13 t hr ough 3- 15
r ear t r i angl e
seat t ube i nt o bot t ombr acket
3- 41, 3- 97 t hr ough 3- 98
3- 65
st eer i ng col umn i nt o cr own
t i nni ng
t op t ube i n pl ace
3- 29, 3- 79 t hr ough
8- 15,
3- 76 t hr ough
3- 80
8- 29
3- 77
Wel co #17 f l ux 8- 4, 8- 15
BRI DGE MATERI AL
det ai l ed descr i pt i on 2- 55 t hr ough 2- 56
CABLE STOPS
gener al 2- 9 t hr ough 2- 10
CANTI LEVER
br akes 2- 5 t hr ough 2- 7
l ocat i on of st uds 2- 6
Sunt our XC br akes YP
CENTER PULL HANGERS
gener al 2- 15
CENTERI NG
r ear wheel 3- 44 t hr ough 3- 45
CHAI N HANGER
gener al 2- 11
CHAI NSTAY
br i dges 2- 17 t hr ough 2- 20
cr oss sect i on 2- 54 t hr ough 2- 55
cut t i ng not ch f or dr opout 3- 8, 3- 63 t hr ough 3- 64
det ai l ed descr i pt i on 2- 54 t hr ough 2- 55
ends 2- 56
l engt h 1- 14 t hr ough 1- 15
CHAI NSTAY BRI DGE
i nst al l at i on of 3- 48, 3- 101
CHAI NSTAYS
f i t t i ng and cut t i ng
heavy dut y i n l ugl ess wor k
3- 37 t hr ough 3- 38, 3- 95
8- 31
CLAMP STOP
gener al 2- 11
COLDSETTI NG
down t ube out of bot t ombr acket 3- 21
r ear t r i angl e 3- 42 t hr ough 3- 44
seat t ube out of bot t ombr acket 3- 16, 3- 67
13- 3
COMBI NATI ON SQUARE
gener al 6-7
COMPONENT SHEET
or der f or m 4-7
COORDI NATE MEASURI NG MACHI NE
Cor dax 9-37 t hr ough 9-38
Numer ex 9-37
CORBETT METHOD, THE
dr opout s r el at ed t o cent er l i ne
i nt r oduct i on
measur i ng f or k bl ade l engt h
measur i ng head t ube t wi st
measur i ng r ake
mount i ng f or k ver t i cal l y
mount i ng f r ame ver t i cal l y
r el at i onshi p of f r ont and r ear t r i angl es
r est i ng f r ame on bui l d- ups
sweepi ng bot t ombr acket f aces
9-28, 9-29
9-27
9-30
9-28
9-29
9-30
9-30
9-28
9-27
9-27
COUNTERBALANCE
f or head t ube dur i ng br azi ng
CRESTS
i l l ust r at i ons
CRI TI CAL TEMPERATURE
of st eel
CROTCH CLEARANCE
i n seat t ube l engt h f or mul a
CUBI T
r el at ed t o st eml engt h
CUSTOM FRAME
pr i ce l i st
CUTOUTS
i l l l ust r at i ons
DAVI DSON
bot t ombr acket shel l s
l ug set s
8-17 t hr ough 8-18
2- 15 t hr ough 2-16
8-5
1-2
1-5
4- 4 t hr ough 4- 5
2- 15 t hr ough 2-16
YP
YP
DAVI SON FORMULA
er r or of 1- 10
13-4
DEFLECTI ON
of down t ube
of seat t ube
DI AL I NDI CATOR
gener al
DI E GRI NDER
gener al
use of i n l ugl ess bui l di ng
DOWN TUBE
def l ect i on of
det ai l ed descr i pt i on
mi t er i ng shor t but t ed end
mi t er i ng l ong but t ed end
3- 19 t hr ough 3- 20, 3- 70 t hr ough 3- 71
pr ot ect or sheat h 5- 9 t hr ough 5- 10
3- 16, 3- 67,
3- 16,
8- 26,
3- 67,
9- 13
9- 12
9- 3
6- 8
8- 29
3- 16, 3- 67, 8- 26, 9- 13
2- 48
3- 9
DRI LL BI TS
gener al
DRI LL PRESS
gener al
DROPOUT
at t achi ng
br azi ng i n f r ont set
br azi ng i n r ear set
chai n adj ust er s
char t
f r ont
st andar d r oad
t r ack or r ear l oadi ng
ver t i cal
DROPOUTS
f i t t i ng of
use of H t ool s
DUMMY BRAKE
use of
i l l ust r at i on
DUMMY HEADSET
use of
i l l ust r at i on
DUMMY REAR WHEEL
use of
i l l ust r at i on
6- 5
6- 9
2- 46 t hr ough 2- 47
3- 26 t hr ough 3- 27, 3- 83
3- 37
2- 41
2- 44 t hr ough 2- 45
2- 43
2- 41
2- 43
2- 42
3- 63 t hr ough 3- 64
3- 49
3- 85
5- 3
3- 29, 3- 35
5- 1 t hr ough 5- 2
3- 45, 3- 48, 3- 100 t hr ough 3- 101
5- 2
13- 5
DYNABRADE
gener al 6- 11
use of 3- 60 t hr ough 3- 61
use of i n l ugl ess bui l di ng 8- 29
EMBELLI SHMENTS
i l l ust r at i on
EYELETS
ext r as f or f ender s
FACE MI LLI NG
of bot t ombr acket
of head t ube
FI LES
gener al
FI LLET BUI LDI NG
descr i pt i on of pr ocess
FI RE EXTINGUISHER
gener al
FI RST AI D KI T
gener al
FI T KI T, THE
gener al
2- 15 t hr ough 2- 16
2- 12 t hr ough 2- 13
3- 15, 3- 50, 3- 66, 3- 105, 8- 26
3- 26, 3- 77 t hr ough 3- 78
6- 3 t hr ough 6- 4
8- 14 t hr ough 8- 15
6- 12
6- 12
1- 6, 6- 11
FI XTURES
bendi ng 5- 9 t hr ough 5- 11
hol di ng 5- 4 t hr ough 5- 9
measur i ng 5- 1 t hr ough 5- 4
FLUX
cl ean up of br ass f l ux 8- 15
cl ean up of si l ver f l ux 3- 15
heal t h war ni ng 3- 13
FORK
bendi ng bl ades 3- 7, 3- 62
bl ade bender 5- 11, 3- 62
cut t i ng not ches i n bl ades 3- 8, 3- 63 t hr ough 3- 64
dr opout s r el at ed t o cent er l i ne
9- 24 t hr ough 9- 25, 9- 29, 9- 36
measur i ng of r ake 9- 29, 9- 20 t hr ough 9- 22
measur i ng of t wi st 9- 22 t hr ough 9- 23, 9- 29
mount i ng on sur f ace pl at e 9- 20, 9- 29, 9- 30
r ake 1- 8, 3- 4
t heor et i cal ( di agr am) 9- 26
13- 6
FORK BLADES
cut t i ng r ecommendat i ons
det ai l ed descr i pt i on
f i t t i ng and cut t i ng
FORK CROWN
Andr ew Hague
Ci nel l i
count er bor i ng
cr oss sect i ons
Henr y J ames
i nser t ed
over l appi ng
r eami ng of
sl ope
st i f f ener s
t hi ckness
Zeus
FORK CROWN RACE SEAT
mi l l i ng of
2- 53,
2- 52 t hr ough
3- 84 t hr ough
3- 30,
2- 39,
1- 17, 3- 5,
3- 31,
3- 31
2- 53
3- 88
YP
2- 40
3- 81
2- 38
2- 40
2- 39
2- 39
3- 61
2- 39
2- 40
3- 52
2- 41
3- 82
FORK J I G
i l l ust r at i on
set up
FORK TWI ST I NDI CATOR
i l l ust r at i on
use of
5- 7, 5- 12
3- 33 t hr ough 3- 34, 3- 88 t hr ough 3- 90
5- 4
3- 34, 3- 89 t hr ough 3- 90
FRAME ALI GNMENT SYSTEM, THE
gener al 6- 12
car e of t he bed 9- 31
checki ng t r acki ng 9- 35
col dset t i ng f r ont t r i angl e 9- 33
dummy hub gage 9- 34, 9- 36
f aci ng bot t ombr acket 9- 32
l i st of component s 9- 31
measur i ng head t ube t wi st 9- 33
mount i ng f r ame 9- 32
r el at i onshi p of f r ont and r ear t r i angl es 9- 34
swi ng ar m 9- 33
use of j ack 9- 32 t hr ough 9- 33
wor ki ng wi t h f or k 9- 35 t hr ough 9- 36
FRAME DESI GNER' S STRAI GHT EDGE
gener al
use of
FRAME REPAI R
pr i ce l i st 4- 3 t hr ough 4- 4
13- 7
5- 4
3- 5
FRAMESET
or der f or m
FRONT CENTER
gener al
FRONT DERAI LLEUR
br azed on
GRI NDI NG WHEELS
gener al
H TOOLS
checki ng f r ont dr opout s
checki ng r ear dr opout s
4- 6
1- 12
2- 3, YP
6- 4
3- 35, 3- 91
3- 49, 3- 101
HAND OPERATED ELECTRI C DRI LL
gener al
HEAD TUBE
angl e
det ai l ed descr i pt i on of
f ace mi l l i ng of
r i si ng and f al l i ng of
st abi l i zer bar
t andemgage
t wi st
HEADSET
l ower st ack hei ght
HEAT DI STORTI ON
cont r ol l ed dur i ng br azi ng
r el at ed t o f i l l et si ze
3- 26,
2- 50 t hr ough
3- 77 t hr ough
3- 20, 3- 72,
8- 4,
9- 14, 9- 28,
1- 16,
6- 4
1- 7
2- 51
3- 78
1- 10
5- 9
8- 6
9- 33
3- 52
8- 19
8- 19
HEI GHT GAGE
Mi t ut oyo Hei ght Mast er 9- 38
phot os 9- 14 t hr ough 9- 16, 9- 19 t hr ough 9- 20
HYDROGEN EMBRI TTLEMENT
and pl at i ng 11- 32
I NSEAM LENGTH
as used i n f or mul a 1- 2
I NTERCEPT POI NT HT/ DT
i n f r ont end geomet r y 1- 17
i n l ugl ess const r uct i on 8- 11
r el at ed t o dr awi ng 3- 5, 3- 53
13- 8
I NTERCHANGEABLE PARTS
The Uni f or mi t y Syst em 9- 1
I NTERCLAVI C NOTCH
r el at ed t o f r ame geomet r y 1- 6
I SHI WATA
compar i son char t 2- 62
di scont i nuat i on of 025 set s YP
EX and EXO set s YP
LED READOUT
on pr eci si on t ool s 9- 3
LOW RI DER MOUNTS
gener al 2- 8
LUG SETS
Ci nel l i 2- 34
Davi dson YP
Haden 2- 35
Henr y J ames 2- 34
Ot suya YP
Pr ugnat 2- 34
Tange 2- 35, YP
LUGS
compar i son of cast and st amped 2- 33 t hr ough 2- 34
i nvest ment cast 2- 32 t hr ough 2- 33
st amped 2- 31 t hr ough 2- 32
MACHI NI ST' S SQUARE
gener al 6- 6
i n bui l di ng f r ont t r i angl e 3- 11 t hr ough 3- 26, 3- 70, 3- 73
i n bui l di ng l ugl ess 8- 20, 8- 24, 8- 27
MECHANI C' S TOOL CASE
gener al 6- 1
MI CROMETER
bot t ombr acket 3- 16, 3- 67
expl anat i on of i t s use 9- 6 t hr ough 9- 8
MI G WELDI NG
l ugl ess j oi nt s- st eel 8- 10
MI NUTE CALI BRATI ON
of measur ement 9- 2
13- 9
MI TERI NG
gener al 3- 56 t hr ough 3- 58
bot t omend of down t ube 3- 19, 3- 71
but t ed end of seat t ube 3- 9
shor t but t ed end of down t ube 3- 9
shor t but t ed end of t op t ube 3- 10 t hr ough 3- 11
MI TERI NG- LUGLESS
bot t omend of down t ube 8- 20 t hr ough 8- 24
but t ed end of seat t ube 8- 12
shor t but t ed end of down t ube 8- 12
shor t but t ed end of t op t ube 8- 13
MODI FI ED BAR CLAMP
i l l ust r at i on 5- 6
i n l ugged const r uct i on 3- 25, 3- 76
i n l ugl ess const r uct i on 8- 28
MODI FI ED C- CLAMP #1
i l l ust r at i on 5- 7 t hr ough 5- 8
i n l ugged const r uct i on 3- 77
i n l ugl ess const r uct i on 8- 28
MODI FI ED C- CLAMP #2
i l l ust r at i on 5- 8
use of 3- 77
N. I . O. S. H. ( O. S. H. A. )
and pai nt i ng r egul at i on 11- 2
O. S. H. A.
see N. I . O. S. H.
ORDI NANCES
and pai nt i ng 11- 2
OTSUYA- MEDALI ST
bot t ombr acket shel l YP
l ug set s YP
PAI NTI NG
accel er at or 11- 29
adj ust i ng ai r pr essur e 11- 10
and pl at i ng 11- 32
br eat hi ng syst ems 11- 13 t hr ough 11- 17
cal i br at i on of mi xi ng cup 11- 26
cl ear coat s 11- 29
compr essor 11- 12 t hr ough 11- 13
decal s 11- 30 t hr ough 11- 31
degr easi ng 11- 24
f or ce dr yi ng or baki ng 11- 30
handl es 11- 21 t hr ough 11- 22
13- 10
PAI NTI NG cont .
heal t h war ni ng 11- 25
l i nt 11- 27
maski ng 11- 23 t hr ough 11- 24
met al pr ep 11- 20 t hr ough 11- 21
pol y- ur et hane enamel ( I mr on) 11- 27 t hr ough 11- 29
pr epar at i on f or 11- 17 t hr ough 11- 24
pr i ce l i st 4- 3
r educer 11- 27
sandbl ast i ng 11- 19
st r i ppi ng ol d pai nt 11- 17 t hr ough 11- 19
t ack r ag 11- 24
t echni ques 11- 32 t hr ough 11- 33
t hi nner 11- 27
t wo par t epoxy pr i mer ( Cor l ar ) 11- 26
vi scosi met er 11- 26
wet sandi ng 11- 19 t hr ough 11- 20
PAI NTI NG BOOTH
l i ght i ng 11- 4
t he shel l 11- 3 t hr ough 11- 4
vent i l at i on 11- 4 t hr ough 11- 5
PAI NTI NG GUN
adj ust i ng needl e val ve 11- 11 t hr ough 11- 12
choosi ng of 11- 6 t hr ough 11- 7
f an cont r ol 11- 8
f an r ot at i on 11- 9
f l ui d cont r ol 11- 9
mai nt enance of 11- 10
pr i nci pl es of 11- 7
PAI NTI NG SYSTEM, THE
i l l ust r at i on 11- 3
PARK STAND
gener al 6- 5
PHOSPHORI C ACI D
met al pr ep 3- 51, 3- 106, 11- 20 t hr ough 11- 21
PLATI NG
and hydr ogen embr i t t l ement 11- 32
and pai nt i ng 11- 32
PUBI C ARCH
and si zi ng of f r ame 1- 6
PUMP PEGS
gener al 2- 10
13- 11
REAMERS
Chadwi ck YP
REAMI NG
chai nst ay hol es i n bot t ombr acket 3- 95
i nsi de di amet er of f or k cr own 3- 7, 3- 61
i nsi de di amet er s of bot t ombr acket shel l 3- 6, 3- 59
i nsi de di amet er s of l ugs 3- 6, 3- 59
of seat t ube 3- 42, 3- 98
REAR END J I G
i l l ust r at i on
set up
REAR RACK
5- 5
3- 35 t hr ough 3- 37, 3- 91 t hr ough 3- 95
br aze- on f i t t i ngs 2- 7
REAR TRI ANGLE
al i gnment by st r i ng met hod 3- 48
br azi ng of 3- 97 t hr ough 3- 98
col dset t i ng 3- 42 t hr ough 3- 44
i n r el at i on t o f r ont t r i angl e 9- 15 t hr ough 9- 17
per suader 5- 10
REPEATABI LI TY
of measur ement 9- 2
RESPI RATOR
di sposabl e 11- 14
f ul l cover age wi t h ai r suppl y 11- 16 t hr ough 11- 17
use of 3- 26
wi t h t wo f i l t er s i n f r ont of cheeks 11- 14 t hr ough 11- 15
wi t h back mount ed f i l t er s 11- 15
SAPO
f r ame al i gnment f i xt ur es
SEAT CLUSTER
St r awber r y wi t h seat st ay yoke
SEAT CLUSTERS
st yl es of
SEAT POST
bi nder sl ot
SEAT TUBE
YP
YP
2- 24 t hr ough 2- 30
3- 42, 3- 99
angl e 1- 2, 1- 11, 3- 3
def l ect i on of 3- 67, 3- 16, 9- 12
det ai l ed descr i pt i on of 2- 49 t hr ough 2- 50
l engt h 1- 2, 1- 3, 3- 3
mi t er i ng
3- 9
r eami ng of 3- 42, 3- 98
13- 12
5- 10
5- 10
1- 7
1- 10
2- 51 t hr ough 2- 52
3- 28, 3- 29, 3- 78 t hr ough 3- 79
SEATSTAYS
det ai l ed descr i pt i on of 2- 55
ends of 2- 56
f i t t i ng and cut t i ng 3- 38 t hr ough 3- 40, 3- 96
t aper of 2- 55
use of sl ugs or t opeyes 2- 31, 3- 96
SERI AL NUMBER
st ampi ng i n bot t ombr acket and f or k
3- 50 t hr ough 3- 51, 3- 105 t hr ough 3- 106
SHI FT LEVER BOSSES
gener al
SHOTPEENI NG
of TI G wel ded f r ames
SI ZE AND WEI GHT
r ecommendat i ons
SOFT J AWS
2- 4
8- 5, 8- 6
4- 5
gener al 5- 6
SPOKE CARRI ER
gener al 2- 14
STANDARDI ZATI ON
of measur ement 9- 2 t hr ough 9- 3
STEEL BAR
1" di amet er
1- 1/ 8" di amet er
STEERI NG
geomet r y
poset i ve- neut r al - neget i ve
STEERI NG COLUMN
det ai l ed descr i pt i on of
f i t t i ng and cut t i ng
STEM
l engt h
STRAWBERRY
seat cl ust er wi t h seat st ay yoke
STRESS RELI EF
by means of shot peeni ng
hol e
13- 13
1- 4 t hr ough 1- 5
YP
8- 5, 8- 6
2- 30, 3- 42, 3- 99
SURFACE PLATE
al t er nat e sour ces
f i ni sh
mat er i al
measur i ng f or k r ake
mount i ng f or k hor i zont al l y
mount i ng f or k per pendi cul ar i l y
mount i ng f r ame t o
mount i ng f r ame ver t i cal l y
si ze
st abi l i t y
t ol er ances
9- 10
9- 10
9- 10
9- 20 t hr ough 9- 22, 9- 29
9- 20, 9- 29
9- 23, 9- 29
9- 11 t hr ough 9- 12
9- 17 t hr ough 9- 18
9- 9
9- 9
9- 9
TANGE
1000 ser i es t ube set s
900 ser i es t ube set s
bot t ombr acket shel l s
I nf i ni t y ser i es t ube set s
i nvest ment cast l ug set s
st amped l ug set s
TAPPI NG
bot t ombr acket 3- 15,
TIG WELDING
l ugl ess j oi nt s- al umi num
l ugl ess j oi nt s- st eel
TINNING
dur i ng br azi ng
TI RE
3- 50, 3- 66, 3- 105,
8- 15,
YP
YP
YP
YP
YP
2- 35
8- 26
8- 8
8- 5
8- 29
cl ear ance 1- 15 t hr ough 1- 16
TOP TUBE
angl e 1- 16
br azi ng i nt o pl ace 3- 76 t hr ough 3- 77
cabl e gui des 2- 9
Col umbus- cr eased YP
det ai l ed descr i pt i on of 2- 49
f i t t i ng & mi t er i ng 3- 21 t hr ough 3- 24, 3- 74 t hr ough 3- 76
l engt h 1- 4, 3- 4
mi t er i ng shor t but t ed end 3- 10 t hr ough 3- 11
TORSO MEASUREMENT
and si zi ng of f r ame
1- 5 t hr ough 1- 6
TRAIL
descr i pt i on
1- 8 t hr ough 1- 9
f or mul a
1- 9
13- 14
TUBI NG
cl amps 3-56, 5-5
Col umbus char t 2-61
composi t i on char t 2-66
i nt r o t o compar i son char t s 2-57 t hr ough 2-60
I shi wat a char t 2-62
over si zed 8- 1
over si zed f or al umi num 8-7
Reynol ds char t 2-63
subst i t ut i ons 2-56 t hr ough 2-57
Tange char t 2-64
t ensi l e st r engt h char t 2-66
Tr ue Temper char t 2-65
var i at i ons 2-47 t hr ough 2-66
UNDERCUTTI NG
descr i pt i on of 8-15, 8-29
di agr am 8-16
UNI FORMI TY SYSTEM, THE
i nt er changeabl e par t s
V- BLOCKS
gener al
VERNI ER CALI PERS
gener al
VERNI ER SCALE
expl anat i on of
VI SE
gener al
WATER BOTTLE
br aze- on f i t t i ngs
9- 1
6-7, 6-8
6-6
9- 3 t hr ough 9-6
6-2 t hr ough 6-3
2-2 t hr ough 2-3
WELDI NG TANKS AND APPARATUS
gener al 6-2
WHI TNEY, ELI
and t he uni f or mi t y syst em 9- 1
WORK HARDENI NG
gener al 8-26
WORKI NG DRAWI NG
di agr am 3-2
ZONI NG
and pai nt i ng 11-2
13- 15
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