Overview

At the time of writing this, I've only just started on the project. I had the idea while building this website, and with some gentle heckling from one of my friends I decided to go for it.

The basic concept is to use a rear triangle from an existing bike, and build a front triangle to suit my riding style. I don't have access to a machine shop during COVID, so I'll be using all my own tools. This means it's pretty unrealistic for me to build a full suspension rear triangle, as I don't have access to any machining equipment. The rear triangle is much more complex than the front. Using a different rear triangle also lets me use a more complex linkage system than I'd be inclined to manufacture on my own with limited tooling.

Welding/Alignment

I welded the front triangle, but it warped more severely than past frames I've built. I think a lack of rigid fixturing caused this. Ordinarily I tack weld all around the joint while the jig holds the tubes in position, but the tubes were free floating in the printed parts. This let them pull towards the heat while I tacked them.

I welded the seat tube/bottom bracket joint first because there's interference between the down tube and seat tube.

I left the head tube long to help prevent radial warpage, as the headset is a press fit.

The head tube was cocked to the left side of the bike relative to the bottom bracket/seat tube. I clamped the seat tube end of the frame to a workbench, put a long steel tube in the head tube, and persuaded it into position.

Main Pivots

I 3D Printed a jig that slides over the bottom bracket with a drill bushing pressed in that let me drill a hole to accept a threaded stand off. This is where the lower link mounts.

Frame Finishing

I painted the frame the same color as my Vanagon because I had extra paint. Parts are slowly trickling in, hopefully it will be rideable within a few weeks!