Wednesday, January 05, 2011

A year has gone and a year has come.

Welcome to 2011.  Its really an arbitrary number but I like new years and I like the fresh start that I feel it brings.  As well as the reflection and the opportunity to improve things...yes I'm talking about resolutions.  No, I'm not going to blabber on about mine either, at least not here.  I don't always have them, I just like them.  I am going to reflect a little bit though.  2010.  6 frames and 7 forks (you could probably count the truss fork as some combination of the two).  I definitely learned something new in doing each one.  I'm still honing my process in this experiment, but with each bike or fork I feel like I spend less time at each step and have a better "feeling" as to what will work and what won't.  I developed new ideas, techniques, and methods by pushing through projects that I would never have known if I hadn't just gone for it and as a result built some of the coolest things, bikes, whatever, that I've ever created.  To me what makes this worth it though is the interactions I get to have with the people who commission me.  In the waning hours of 2010 I found myself in a conversation with Elder Heinsius, whose frame I finished only an hour before. He's somewhat new to riding bikes, but not at all unfamiliar with them.  He's been getting increasingly excited about his build and was always stoked to check out his work in progress.  What he told me that I think in the end was that over the many conversations we had in conceptualizing his bike, we didn't talk about bikes all that much.  I mean we did the measurements and the jargon and whatnot, but we really talked about guitars, music, movement, how the Elder gets into things, what fuels his passions.  And through those conversations I really got into his bike.  I think I cranked it out in a week even being laid out two days with a cold.  Not to toot my own horn, this is just what makes it worth it for me.  Getting to know someone in ways that I otherwise wouldn't through building him or her a bike.  Translating conversation and abstract ideas into functional art that I hope represents that person's personality.  I think I can say that of every frame I built this year--it represents its rider's personality.


horseshoe chainstay brace, clearance for 26x2.5s, mud, and a triple.


That being said....at this point I have a hard time with the idea of expanding on what I'm doing.  I kind of like it just where it is.  I already spend entirely too much time in the garage and am at the point where the other things I want to do take a back seat.  I give myself cabin fever here in the winter.  I get kind of freaked at the idea of filling 10 or 20 orders, even knowing what that means.  Right now I have one bike in que and I'm so OK with that.  I need to do something else, have another job, figure things out, go outside more, whatever.  Right now everything in my life comes in very intense waves and then I sort of freak out and have to get out.  I wonder what part of it is my personality and what part of it has to do with spending the four intense summers fighting fires and completely throwing off my balance.  Anybody have any thoughts?

Happy New Year.

Thursday, December 23, 2010

Head tubes (warning: this is probably gonna be dorky.)

I started Elder Heinchez' bike the other day and it features something I don't usually incorporate on most builds....a short tube.  100mm.  This is the shortest I've ever put on a bike....29ers included.  I like to leave them as long as possible, and, well, this one is as long as possible.  Longer head tubes just make sense from a physics and engineering stand point.  They diffuse the stress on the headset cups and bearings from the leverage of the fork and the varying forces applied to it as the front wheel rolls over and impacts the terrain and braking forces are applied.  Imagine the lower headset cup as the fulcrum of a lever in the simple machine sense of things and the upper cup as the object being moved by this machine.    The closer the upper and lower cups are together the easier it is to stress this area (loose headsets, ovalized head tubes, etc.)

A number of factors will dictate the length of a head tube in a bike's design, but ultimately the build of the rider is going to be the limiting factor.  A rider will have a maximum seat height and therefore a maximum or minimum handlebar height.  For most mountain bikes I figure a handlebar height that is equal to the saddle, unless the rider knows he wants handlebar drop.  The other considerations immediately affecting head tube length are:

fork length (axle to crown)...longer travel forks are, well, longer

bottom bracket height--raises/lowers the rider over the axles.  A taller BB warrants a longer head tube.

seat tube angle--a slacker ST will lower rider position

component choices--a riser bar leaves less room for a head tube.  Usually this is not critical but is definitely something to be considered when that space is going to be at a premium.

you could probably also argue that ETT length and head tube angle will affect head tube length, but it seems negligible and these are both design considerations that hold a more important function.

there is no reason to have an excessive stack of headset spacers on a custom bike unless a wide variety of positions is desired by the rider.  To me over 20mm of spacers is excessive (think of the lever and fulcrum, your headset, being worked from the handlebars, too).  Allow for dynamic adjustments for comfort within a range.  Most people as they age, though, fancy comfort (higher handlebars) over speed (lower, more racy position).

The Elder's bike is interesting here.  He is built stout with a long torso and long arms and carries a very good portion of his weight in his upper body.  He wanted a bike that is stable and that gives him confidence on the descents.  Until now he's often felt like the front end on the downhill is a precarious balance point.  This bike will have slacker angles and a lower BB than most that I do, but given his build and experiences, I think this will suit him very well.  He's also the type of rider to barrel through the hard parts, no compromise to parts, so stability is key.  This was a tricky design to work out but the overall lower center of gravity left me with a 100 mm head tube and probably not much room for rise in either the stem or the handlebars.  Now here's where I think this shorty HT is just cool:  with the oversize tubes (31.8 TT, 34.9 DT) and giving myself enough room for a nice fillet on top and enough room to swing a Fox Fork around on the bottom, the top tube and down tube intersect.  This is coming out to be the most precisely mitered bike so far.  The pics below are of the build sequence so far.  I ended up tacking the top tube and head tube and will clean it up as a sub assembly before tacking the down tube.  The seat tube and BB are already tacked and sleeved as is pretty standard.  All said I'm pretty stoked on it.





Wednesday, December 15, 2010

Finnito!

Shawna's bike is finished.  Dun.  tapped and faced and sanded and all that.  Purdy too.  It'll be cool to see it under powder.  The brake bridge is an extension of the upper rack mounts and should be very stiff.  In other shop happening....I got a sweet custom one off handlebar from the Volcano in the mail this summer and have yet to figure out what to do with it but I sanded the rust off and gave it a clear coat of engine enamel and decided to turn the VooDoo into a winter commuter.  All the hydraulics need to be rebuilt though.  The brakes don't work and the fork needs new seals.  Good thing the snow isn't sticking yet.  









The photos are of something that has become somewhat of a ritual to me...as in the new bike gets shown off inside the house for a brief spell and I usually spend the rest of the finished evening staring it and marveling in its creation.  

Elder Heinchez is up next.  He's on the new side to mountain biking and has been riding on mostly borrowed (and ill-fitting) equipment.  It'll be a squat, stable 26" with a long top tube that'll barrel through tough spots in the trail.  The way the Elder described his bike to be is like his guitar playing...he does a lot with a little.  To me that says fat tires....yesss.

Monday, December 13, 2010

Progress

Shawna's bike is coming along.  It has taken a while but I really don't feel like I've put that much time into it.  Its been short days really and lots of days off last week.  Here's a photo update of the progress and a few randoms.


Paragon order came in.  I love ordering from them.  Their stuff is oh so fine.  Ten pairs of Bottle opener dropouts.



Checking things out before moving on.  Tire clearance, alignment, chainring and derailleur clearance.


The nicest of the lugs out of the soak tank.


Mock up with a 68x107 BB, a 9 speed cassette and a 26/36/48 crank, old XTR.  The chainring clearance is a little tight with this setup but I like the chainline with the 107 bb so I'm going to dimple the chainstay on the outside.


Fitting up the seat stays.  This is a piece of 1/2" x .035 chromoly.  This bike was just begging for some straight gauge here.  I looked at some tapered and other options but they just didn't look right.  This was the last piece I had though so I had to track some down.  Thanks Garro.


Dimpling the chain stay.


The dimple.


Blended the head tube extension.


Making some classy seatstays out of straight gauge.  Not the best braze here


Finished and ready for attaching to the bike.


The fork is done and now its cleaned up.  Paul U-brakes.  I haven't hooked them up to a lever yet but they feel strong.


Tomorrow I get to put these things together into something cool.  I think I'm going to like this setup.  That's all for now.  Goodnight.

Friday, December 03, 2010

Chain Stays and Dropouts

I've been tending to mitre the front triangle and chain stays together, braze that whole thing, then do the seat stays.  Here's some pics of the chain stay/dropout work I did yesterday.


Here's the addition I do to the drawing to account for tire and chainring clearance when building the rear end.  Using the centerline of the bottom bracket from the original drawing I draw the back half of the BB shell--this one is 68mm--and extend a centerline to the rear axle to split the difference of 135mm.  I draw in the chainrings by using an assembled crank and BB.  This one is an old XTR square taper with 26/36/48 chainrings that is close to what Shawna will be running and for mock up I used a 107 mm shell.  Little rings have shown to be the biggest obstacle in chain stay clearance.  The vertical line to the right of the half bb shell represents the minimum chain stay spread at that point (i.e. tire clearance).  For this drawing I wanted 55mm spread at the full diameter of the tire.  I lay the stays down and line them up to see if they'll fit how I want.  This bike is getting True Temper bent oval chain stays.  Recently I've been using the S-bend stays, but the single bend ovals are good riding stays and I think they will fit this bike quite nicely.  They will take some working though.


Into the tire clearance machine.  I came up with this along the way last winter after seeing how some bikes needed more clearance.  Here is the chain stay pre tire clearance.  I mark the block so the stays sit at the same place and check the alignment as all parts of this machine sit pretty loose before clamping.


...and after the squish.  I measure the jaws to ensure they get squished the same.


Finished product.  I drew the lines on the stays thinking that's where I would center the bend, but I wound up not using that...mostly because the machine didn't want to do it that way.





Chain stays and dropouts brazed.  This bike is using Henry James cast stainless plug dropouts.  These things are super easy to use and make for a seamless finish.  The double eyelets are cast into the dropout and are very clean.  That's all for now.  I put in a late late night last night but the front triangle and chain stays are all brazed up and its sitting in the soak tank now.  I'll probably get back at it next week, but maybe I'll get some pics of the brazing up in the meantime....peace.

Thursday, December 02, 2010

Back in the Shop

I finally got back into the shop today even though I've been home for at least two weeks now.  I guess I've been unburying my stack of neglect from the past eight months of mostly absence.  But now that's coming to an end...the shop's clean, the firewood is coming along even though its already December, and today it was warm enough to get a good spell in the shop that lasted well into the evening.  That's really why I haven't gone out there...its been cold as balls here and its usually colder in the shop than it is outside.

Anyways I'm onto Shawna's....bike....actually I don't really know what kind of bike it is. That's sort of scary.  I guess I've become partial to building mountain bikes or at least fillet brazed bikes.  It'll be cool though.  Some sort of randoneur/tourer with 650b wheels and lugs throughout with Paul's new racer brakes.  It'll be crazy.  It took a few renderings and I ended up changing it up again today and slackening the angles half a degree and lowering the BB.  I think it'll work out well.

The request back in the east was more pics of what I'm doing and we just got a new internet connection up and running so we'll see if the uploads go a little more quickly.  Here's a show and tell of today's work.



facing the head tube/top tube lug so a head tube extension sits flush


the lugs do not have an even face from the casting injection.  the uneven color is where I started to face the down tube lug.


head tube/top tube lug and 20 mm extension.  The extension is a piece of 1 3/8" x .058" chromoly


both the lug and the extension are faced for a seamless fit.  when the frame is brazed I will sweat silver through the whole unit here and then clean up the finish with a file.  (the extension is slightly smaller)


marking the top tube mitre at the seat tube.  the head tube is already mitered.  I mitre everything with hacksaw and files at this point so I do them one at a time to minimize any chance for error.  These machined tubing blocks are invaluable to me.  from goodtimes bicycles


tacked BB/seat tube.  The discoloring is because I defluxed with a wire wheel instead of soaking.  I'll be fillet brazing the bottom bracket joint and chainstays.  This just seems to make more sense.  Lugs are a very big design constraint (certain size sockets placed at certain angles) and tire clearance is not a place where I want constraints.  Plus nice fillets here just look cool to me.


Mitering the downtube seat tube junction.



the first snow ride on the year on the General Lee.  I had to disconnect the brakes so they didn't pack up with snow as bad.  Enjoy y'all.  See ya.



Monday, November 01, 2010

The Fall Tour


The fall tour has been going on for me for at least the last month now and usually does when I get my freedom from the Forest Service.  Traditionally though, Wenger and I do something involving a bike trip, but this go 'round he's nowhere to be found and I've been more making do with the stuff you've been reading about.  I caught a ride back to the homeland and when I got to Athens there was all this buzz over The Fall Tour, and after enough days of hearing about I decided I needed to go up and check it out.  Now I've heard of this event before when I lived in Athens, but never was convinced to make it.  This year was the tenth anniversary, though, so the riding was to be scaled back from the long days of the Tour's repute to accommodate the masses.

Based somewhere in North Georgia,  The Fall Tour is four days of abnormally long (for most people) rides on trails that may or may not exist and roads that may or may not take you there.  The event itself is a huge personality crisis of all walks of cycling ranging from mountain biking to touring to road racing with plenty of spandex and beer for all and at least five separate competitions rolled into the race and jerseys recycled from God know where and when to designate the leaders of each category.  Take it as you will and there's something here for everybody. The crowd this year comprised of mostly Athenians, a few Atliens, a few North Carolinians, a recent transplant to California and myself.  There was even a local boy who raced in the Tour de France this summer and brought substantial publicity to Athens from Phil Liggett and Bob Roll,  how 'bout that?  I never formally met the lad, but everybody said he was real nice and beyond all that he can apparently rip it up on a mountain bike.  Dude won the overall race and was never much out of second on any of the downhills and probably even won some of them.


I really had no idea what I was getting into aside from four days of riding and camping, and no one, or at least no one who had anything to do with the event knew I was coming, or who I even am.  I ended up hitching a ride up with Loehr, of APE06 fame, who seemed to think there'd be no problem in my arrival.  I decided I'd be best to show up with arm loads of food.  People with food are always welcome.  Food is provided with your entry fee and Kelly (Tour Director) was always busy at work in the kitchen cooking it up for everybody, but supplements are always welcome.  We missed the departure for the ride that day, but I managed a ride with the two ladies hanging out in camp following my favorite fishing river from my youth.  They jabbered on and on and I just wished I had my fishing pole.  I ended up ditching out early and heading downstream to scout some of the old holes.  When we got back the tour rolled in just behind us full of whooped and hungry cyclists.  Some of them looked pale, even green, starved, and I started to wonder what I was in for.  Food was cooked and consumed and amidst all this I started to find myself in familiar company...old racing buddies, southerners, cyclists, and beer lovers all sitting around a camp fire after a long hard day on the bike, shootin' the breeze with a slow southern drawl that only gets slower when you find yourself around others and so much beer.


More people arrived Saturday for about 50 in all and among them.....the esteemed Puc-Puggy, the Volkscycle slayer, the New England Red Devil, and Niner Mike with the Paper Bike.  I parked the old Breezer next to the paper bike for effect and it was definitely drawing more attention.  Beers were put down in the morning that lasts forever and just before roll out a tub of brownies circulated the crowd for anyone who was interested....mmmm....yes please.  The ride today would be known as Hog Wild....or Wild Hog backwards....whatever.  We rolled back up the river road I used to fish and stashed some beers in the river for later consumption and then on to the Tate City Mall where the ride would regroup for a sprint to the NC state line.  Then a timed section up and over Hog Wild and back to the river.  I rode off ahead of the group to catch the finish of the sprint and try to avoid the race and while that part worked my attempts were futile and I was soon amidst the race heading up Hog Wild and so I thought I'd better put in some effort.  This trail meandered around the flats in the valley crossing a creek and hopping over some logs and I found myself behind some people walking when I didn't want to be so I hopped off did some super jumps and the Breezer floated through the air next to me and five people were now behind me.  I had forgotten that the Breezer still is the best climbing bike I've ever known and despite some rather high gearing I found myself charging up a hill in a race and remembering why I quit racing in the first place.  It gets worse though.  About halfway up the mountain the trail doglegs and turns you straight up and over forcing you to dismount and I found myself in the familiar position of eyes looking to the ground two steps in front of me, twenty something pound object on my shoulder marching straight up a mountain.....uuugh.....work.  I remembered why I am retired.   My T-shirt was soaked through and I then remembered why I used to wear bike clothes...sweat.  Its all coming back to me.  I got to the top and had myself a beer though the race continued on.  And not a single person passing through could say they weren't racing either; the world around you just becomes you.  I opted for the skins jersey and pedaled on down to the river where the ride gathered for more beer.  I'd fallen back to somewhere around last place if you're counting.


The ride was done it was a short one, but the race was not over so for formality there was another race section back on the river road but for me and a few others there was a swimming hole.  Puc took the nod and dove in before anyone could back out and came up in a shrill scream and I went next and the Volkscycler took some serious convincing before he'd do it but he did and we were all grateful for having gone swimming in the cold river with no sunlight.  We rolled back to camp where three batches of chili were cooked along with some chicken and pics were projected onto a screen of the day's ride and stories were told and people were fat and happy and I decided I was over the whole camp fire drinking scene and I went and snuck off to bed.


Sunday would bring another group of fifty plus riders racing to the top of Glassy Mountain and back down through winding sections of singletrack and gravel road and even a little bit of pavement.  Beers were again stashed in a creek before the race climb though I always carry mine and afford myself the time to drink them when I want and people make fun of the huge pack I end up riding with and I wonder why it needs to be so big and what exactly I fill it with.  No matter, my legs were feeling good and I again found myself in the middle of a race up a mountain....this time on a dirt road with room to pass and still on a bike that wants to do nothing but climb.  I thought of ol' Fred Birchmore and Bucephalus and their friendship as travel partners and realized the personality of my own steel horse.  The Breezer was really what pushed me that day.  She just wanted to go and just kept begging me to dig in the spurs and kick it in gear....I gave it all I had and she still wanted more.  I finished the climb making a move to drop the two riders on my tail for a top ten finish and found myself right back in racing mode....as the Foust would say, "Its always a race."  People start to take notice when they get old schooled.  I just think its fun.  The downhill would be an individual time trail.  I found myself somewhere in the middle between the people who cared and the people who didn't.  I think my ways may have down right offended some people as I refused to put my tire right on the line in starting my time trial.  A few people understood though.  I started back in a track stand for a drop in entry.  And go.  I made the steep downhill with arms burning from pulling back the levers of the cantis.  There's a reason these things went away.  I passed the checkpoint thinking only how much harder these steep downhills are on a rigid bike.  This stuff hurts.  A short climb then a nice rolling downhill....now this stuff's fun.  What a sweet trail.  Cross the creek and up for time and cheering and beers.  And as he noted...the guy behind me on the full suspension didn't pass me. Woo-Hoo.  

I opted to skip the hot-dogs in camp that night and go to Bobby & Betsy's house considering the threat of rain and that I had no tent.  Its always great to catch up with them and their family and in the morning we could just ride from their house.  And so we did despite the huge thunderstorm that rolled through that morning.  We pedaled and pushed through the steep and soft dirt roads that lead to some of the finest trails anywhere in the middle of a wet fall morning in north Georgia with the sun trying to poke its face through the clouds of a lingering morning thunderstorm.  We rode up and down the trails and were brushed with wet yellow and red leaves transferring their moisture over to our clothes, but we were never actually rained on.  Occasionally the tunnels of Rhododendron would open up and give way to a view of the surrounding mountains.  There is nothing like this in the west.  I topped the mountain where the big ridge downhill takes off just as the first rider of the tour was launching his downhill time trial.  And fortunately for the tour, Puc was just behind me exactly where the fork in the trail is where he hung out to direct the riders who would have otherwise ended up in town hours later.  We made our way down big ridge after the race...me on rigid bike and Puc with no brakes, alternating the lead and stopping to clear the morning's blowdown and the tour was waiting at the bottom for us and the next section...Rock Crusher.  Now this was an awesome section.  A rolling downhill, never too steep but the trail's pretty washed out and so it requires some committing moves.  Having cantilever brakes instead of discs I was not able to properly slow myself and was forced to go around anyone who looked twice at a line, sometimes blindly into a wheelie-drop move.  I pulled them all off though and passed some riders I would have thought to be faster.  Yeah Breezer.  Hootin' and Hollerin' till trails end.  This is how we roll.  And then back to the cars parked for shuttle and the coolers of beer waiting at the end.  Thanks to Kelly and Darryl and Jeff and YT and all who make the tour happen year after year.  Maybe I'll be back for another round and you can be sure if I do I'll be bringin' some hurt from F-town.