[Oneway]

Does anyone make one or two frames at home or is the fixturing too difficult? I'm curious if it is doable. I'd need a tube set and I imagine a difficult set up.

I'd like to try to replicate a circa 1968 Lygie with extra long (comfortable) wheelbase, long back stays, short top tube perfect for touring. Likewise I contemplate a weather proof commutor with lights, fenders and enclosed chain.

[stdu007]

seam to be a beautifull project ... but not an easy one ... good luck !!!

[HandsomeRyan]

There are people who do this but it isn't cheap.

Another option is to enroll in a "frame building school" where you can use someone elses equipment. (there are a few out there, try a google search).

[Oneway]

Yup. $2-3K range. I guess this makes more sense than trying to much up something solo. It is interesting to think about some kind of kit.

United Bicycle Institute Bicycle Mechanics School Offering Mechanic Certification and Frame Building.
Bicycle Framebuilding School
Frame Building Class

[Industry_Hack]

I can put you in touch with someone that can build your frame for you. To build a jig, and buy the welding equipment and other necessary tools would cost more than a custom frame. Then there's the skill issue too. If you want to build a bunch, then it's worthwhile.

[IanHighfield]

Originally Posted by Industry_Hack

I can put you in touch with someone that can build your frame for you. To build a jig, and buy the welding equipment and other necessary tools would cost more than a custom frame. Then there's the skill issue too. If you want to build a bunch, then it's worthwhile.

What this man said in spades.

You need a sound jig. This piece of gear is of more value than 100 frames and more difficult to build in the first place. Then there is the welding. I've been at steel frames for 4 years now and I'm just now getting decent.

Worthy project, difficult task.

[Oneway]

I value your thoughts and trust all the offered advice.....but, ever the contrarian, what if one wanted to copy an existing frame? What do you suppose finished tolerances should be on lengths and angles for different parts of a frame?

Couldn't I, er, one build a jig very simply, even with foam or blocking to position tubes and finished lengths? I'd need four inch long lugs to hide poorly cut miters and un-wetted brazes, at least that is what I should have had when I brazed-up a tandem frame from a couple of bikes when I was a 14 year old.

I guess I am regressing. As long as I’m day-dreaming, I wonder where “one” could find lugs, tubes and fork ends?

[Industry_Hack]

Originally Posted by Oneway

I guess I am regressing. As long as I’m day-dreaming, I wonder where “one” could find lugs, tubes and fork ends?

Have you tried the internet? When I was doing some research on new steel tubing, I found several companies selling tube sets, lugs, etc.

A quick search shows that Henry James offers all the goods you'd need. Note that his jigs can be had for $2,800-3,600.00, depending on your needs.

[IanHighfield]

Oneway: Look for a book of basic machine principals. Any library will have such. Internet should yield also. Most of the parts you long for can be made at home with basic tools - no CNC required. The men in my group have shown me how rear dropouts and front fork ends are pierced from flat stock of the proper thickness. Steel stock, alloy and carbon fibre can all be cut to shape. My shop makes all its frame bits. Of course most of these are produced on machine equipment now, but that was not how it used to be. A determined man with a jeweler's saw and a Swedish mill can make most anything.

It's helpful for the curious cyclist who yearns to build bike bits to learn of the techniques that go into modern metal and polymer shaping. There is lost wax and sand casting of metal. CNC machining. Sintered metal pressure forming, and liquid metal injection molding. These last two techniques are fairly new compared to wax and sand casting.

Working of polymer-based reinforced materials is essential in today's bikes. Read of fibreglass working. Make some small object of glass. Make a carbon fibre seat post. Yes, you can buy one. But what will you learn of it?

I cheer the maker of homebuilt bike parts.

(Swedish mill is a file)

Ian

[Industry_Hack]

I suppose you could make a frame jig from wood. I'd use something like laminated oak plywood cut into strips and screwed to more plywood. You only need the jog for tacking it all together.