The bicycle thread
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  1. #1
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    Dec 2009
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    The bicycle thread

    I've been wanting to start a bicycle themed thread for awhile now. If any of you guys do any frame building or custom assemblies, it would be cool to see them. Post 'em up! I'll be giving an inside look into how I do it here as well.


    IMG_0189 by Zanconato Custom Cycles, on Flickr


    IMG_0126 by Zanconato Custom Cycles, on Flickr


    IMG_0201 by Zanconato Custom Cycles, on Flickr


    IMG_0220 by Zanconato Custom Cycles, on Flickr


    IMG_0260 by Zanconato Custom Cycles, on Flickr

  2. #2
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    Sep 2010
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    Re: The bicycle thread

    Very nice work, I went through your flickr I like it.
    Miller Maxstar 200 SD
    Piperliner #10 Gold

  3. #3
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    Mar 2010
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    Victoria, BC
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    Re: The bicycle thread

    SSSHHHHhhaaaWwwing!
    200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.

  4. #4
    Join Date
    Oct 2012
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    404

    Re: The bicycle thread

    Does this count? One of my high school autobody students built this from a 20" bmx for SkillsUSA competition.
    Attached Images Attached Images    

  5. #5
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    Re: The bicycle thread

    Here's my bike that I built back in 03'.
    You are way beyond my attempts Zank, very nicely done.
    Awesome fixture by the way (I forget the name, Paragon maybe?)

    I made some for my friends too.
    Here's a link to my photobucket bike pics.
    http://s174.beta.photobucket.com/use...postlogin=true
    Buy American, or don't whine when you end up on the bread line.

  6. #6
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    Apr 2010
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    Re: The bicycle thread

    zank

    It's about time that someone like you showed up; new - but old school.

    Second to fourth photo, you left a lot out.

    No pun intended, but flame the forum with your technique.

    Opus

  7. #7
    Join Date
    Aug 2011
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    england
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    Re: The bicycle thread

    making a start on a chopper style bike with kids next week.
    got a load of bikes they have grown out of or accumalated over years were going to use.

    been looking on the atomic zombie site at some of their ideas.

  8. #8
    Join Date
    Nov 2005
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    Nashville, TN
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    3,380

    Re: The bicycle thread

    Great Work Z. I enjoy looking at bicycle frame work. I have much respect for bicycle frame builders.

    I built a track frame 1996. Raced it at the 1996 olympic trials at Trexlertown PA. Used Combination Of Richard Talbot "designing and building your own Frame set" and Tim Patarek Framebuiling manual.

    I have fabbed a coulple of recumbents.

    Look forward too seeing post from frame builders.

  9. #9
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    Re: The bicycle thread

    Awesome job Zank, it looks amazing.
    I'm also interested in seeing your method. This has been along time interest of mine but not really knowing were to source the materials has made it tough, that and time, hah. I had met a local guy who builds custom bikes but he was not to thrilled on telling me were he sourced his material from. He was kind of a dick to be honest.

    One of my first interviews as a welder was at Seven Cycles but, lack of experience pretty much knocked me out of competiton.

  10. #10
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    Feb 2013
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    Re: The bicycle thread

    Years ago I always wanted to build a BMX frame. Pretty straight forward fixturing wise (if you only want to make one and you're not in a rush). I never got around to it. Closest I came was repairing a couple old Stardard Trail Bosses w/busted seat stays. I reached out to the builders at FBM and they proscribed a process. They stayed together. I was impressed with their willingness to share info with a harmless stranger. Very cool.

    Lugged road frames and Ti is a whole nother world! Great stuff.
    Syncrowave 300
    Maxtron 450, S-52E, 30A

  11. #11
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    Re: The bicycle thread

    I'm so excited that there is interest in this thread. I love reading the stories.

    Funny how there are already a few stories showing the spectrum of how willing (or unwilling) some builders are with helping people who are interested in the craft. I've always wanted to give back. I guess it just depends on a person's personality and how confident he is with his business. We'll just leave it at that.

    I'll definitely get more info up on the brazing. I am working on videos too. I generally build the front triangle first and make sure the alignment is where I want it before adding the rear end. The copes are the same as if it was a welded frame. Fit up is just as important with lugs. Any gaps and the frame will pull. After I dry fit the front end and make sure everything is how I want it, I clean everything extremely well, coat everything in flux, assemble it back in the fixture, and then do a small tack braze on all joints. Then I pull it out of the fixture and check the alignment. I can still make some corrections if I need to. Then I braze it fully and recheck. Here is what I am shooting for in terms of alignment.


    IMG_1748 by Zanconato Custom Cycles, on Flickr


    IMG_1749 by Zanconato Custom Cycles, on Flickr


    IMG_1750 by Zanconato Custom Cycles, on Flickr


    IMG_1751 by Zanconato Custom Cycles, on Flickr


    IMG_1752 by Zanconato Custom Cycles, on Flickr


    IMG_1754 by Zanconato Custom Cycles, on Flickr

    I was pretty happy with that one.

    Mick, the extra flux just makes it a lot easier to soak off and clean. It really saves me a ton of time in the long run.

  12. #12
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    Re: The bicycle thread

    Neat. Whos surface plate? I've never seen one what wasn't contiguous. The white band looks cool provided it certs every year.
    Syncrowave 300
    Maxtron 450, S-52E, 30A

  13. #13
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    Jun 2011
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    Princeton, NJ
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    Re: The bicycle thread

    Nice work, Zank. Nice Anvil fixture too.

  14. #14
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    Re: The bicycle thread

    Pretty incredible work Zank. Very nice to see others who care about the zeros on the other side of the dot .0001 and have nice equipment to do so.

    Here is my old bike back when I had a regular 9-5 and no kids.












  15. #15
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    Re: The bicycle thread

    Damn that's sweet. You DH guys get all of the cool tech.

  16. #16
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    Jan 2013
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    weiser idaho
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    Re: The bicycle thread

    for the bicycle thread, rat rob. Just a little welding to widen the lower frame to fit the bigger tire.
    Attached Images Attached Images  

  17. #17

    Re: The bicycle thread

    Beautiful work.

  18. #18
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    Re: The bicycle thread

    Beautiful bikes Mr Zanconato, what tubesets do you use?


    Although I am what you would call a weightweenie when it comes to bikes and love lightweight carbon stuff, I still have a thing for brazed lugged bikes.
    Here is one of my bikes, heavy by proper standards, but light for a steel bike @ 8kg



  19. #19
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    Re: The bicycle thread

    Quote Originally Posted by taz00 View Post
    Beautiful bikes Mr Zanconato, what tubesets do you use?


    Although I am what you would call a weightweenie when it comes to bikes and love lightweight carbon stuff, I still have a thing for brazed lugged bikes.
    Here is one of my bikes, heavy by proper standards, but light for a steel bike @ 8kg

    here's one for ya
    Attached Images Attached Images  
    --------------------------------------------------------------
    www.becmotors.nl
    yup, I quit welding.. joined welder anonymous

  20. #20
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    Re: The bicycle thread

    Amazing work Zank! This one i built from plans from a site called Atomic Zombie, and some scrap frames.


  21. #21
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    Re: The bicycle thread

    That's a very stunning craftsmanship! I'm speechless. I can't make a huge project like that! It's an impressive piece of work!
    PlasmaCam CNC cutter
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  22. #22
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    Re: The bicycle thread

    Zank, what flux and rod are you using?

  23. #23
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    Re: The bicycle thread

    I'm not a bicycle builder, heck, I'm not even much of a bicycle rider Zank, but I absolutely love your precision, your attention to detail, and your nice clean shop! Beautiful work!
    -Dan

  24. #24
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    Re: The bicycle thread

    Dan, thanks for the kind words!

    Kaz, I use a 48% silver rod from a company called Cycle Design. Flows really nice. They also sell a flux from Superior that is really nice. Has a really long active time and rinses very easily. Great stuff.
    Last edited by zank; 03-21-2013 at 07:37 PM.

  25. #25
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    Re: The bicycle thread

    Taz, I generally use Columbus for road and cyclocross bikes and True Temper for mountain bikes. Each company has their strengths.

    Sweet Colnago. I've loved that paint job for ages.

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