Cycle Truck

This is what I'm keeping from the donor frame. It is mounted on my front triangle frame fixture.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:55:49 -0700

AlexAndChristine
This is what I'm keeping from the donor frame. It is mounted on my front triangle frame fixture.

A test head tube/downtube joint mitered and brazed. I did 3 tests and cut them apart before doing the final joint. I wanted to make sure that I was getting a good miter and brass penetrati ...

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:55:27 -0700

AlexAndChristine
A test head tube/downtube joint mitered and brazed. I did 3 tests and cut them apart before doing the final joint. I wanted to make sure that I was getting a good miter and brass penetrati ...

Inside the joint.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:55:45 -0700

AlexAndChristine
Inside the joint.

Mitering on the lathe. I built a guide for doing this miter, it is a 2.5" cubic block of aluminum with a 1.75" hole in it. I mount it instead of the toolpost on the lathe.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:56:05 -0700

AlexAndChristine
Mitering on the lathe. I built a guide for doing this miter, it is a 2.5" cubic block of aluminum with a 1.75" hole in it. I mount it instead of the toolpost on the lathe.

Top view of lathe mitering.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:56:35 -0700

AlexAndChristine
Top view of lathe mitering.

The whole lathe in action.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:56:14 -0700

AlexAndChristine
The whole lathe in action.

The hole saw is just coming through the tube.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:56:44 -0700

AlexAndChristine
The hole saw is just coming through the tube.

The cut is made.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:56:46 -0700

AlexAndChristine
The cut is made.

The miter has been cleaned up a bit with files and the head tube fits nicely.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:56:52 -0700

AlexAndChristine
The miter has been cleaned up a bit with files and the head tube fits nicely.

The head tube and cargo tube have been mitered and are mounted on the front triangle fixture along with the donor frame.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:57:03 -0700

AlexAndChristine
The head tube and cargo tube have been mitered and are mounted on the front triangle fixture along with the donor frame.

Head tube/cargo tube junction.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:57:57 -0700

AlexAndChristine
Head tube/cargo tube junction.

Head tube/cargo tube sub assembly.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:57:40 -0700

AlexAndChristine
Head tube/cargo tube sub assembly.

The frame is brazed together.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:57:59 -0700

AlexAndChristine
The frame is brazed together.

Head tube/cargo tube/downtube junction. There is a lot going on here.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:58:07 -0700

AlexAndChristine
Head tube/cargo tube/downtube junction. There is a lot going on here.

Downtube/BB junction.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:58:28 -0700

AlexAndChristine
Downtube/BB junction.

Cargo tube/seat tube junction. I added a gusset to spread the load and because my cargo tube was 1mm short and I didn't want to remiter the top tube.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:58:34 -0700

AlexAndChristine
Cargo tube/seat tube junction. I added a gusset to spread the load and because my cargo tube was 1mm short and I didn't want to remiter the top tube.

Alistair gives the bike a spin. This cargo box is temporary until I build a rack.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:59:40 -0700

AlexAndChristine
Alistair gives the bike a spin. This cargo box is temporary until I build a rack.

From a ride to West Seattle

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:59:43 -0700

AlexAndChristine
From a ride to West Seattle

Bike in profile

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:59:38 -0700

AlexAndChristine
Bike in profile

My hacky temporary box. It is made from muffler clamps and U channel.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 09:59:55 -0700

AlexAndChristine
My hacky temporary box. It is made from muffler clamps and U channel.

AlexAndChristine's photo

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:00:25 -0700

AlexAndChristine

Scribing the miter on the support bars. I used a block of aluminum with a small hole punched in it as a gage.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:00:41 -0700

AlexAndChristine
Scribing the miter on the support bars. I used a block of aluminum with a small hole punched in it as a gage.

The miter is partially rough cut on the grinding wheel.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:00:44 -0700

AlexAndChristine
The miter is partially rough cut on the grinding wheel.

The miter is tested on a piece of tubing

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:01:05 -0700

AlexAndChristine
The miter is tested on a piece of tubing

Two support bars mitered

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:01:16 -0700

AlexAndChristine
Two support bars mitered

Two support bars and their component pieces. I am inserting tubes into the ends of each support bar to beef them up where the rack mounting bolts will pass through.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:01:27 -0700

AlexAndChristine
Two support bars and their component pieces. I am inserting tubes into the ends of each support bar to beef them up where the rack mounting bolts will pass through.

Rack mounting bolts inserted (but not yet brazed or filed flat)

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:01:33 -0700

AlexAndChristine
Rack mounting bolts inserted (but not yet brazed or filed flat)

I don't have a file with a half inch diameter, so I thought I'd try mitering on the lathe. I also don't have a hole saw, so I did it with drill bits. The tubing is secured in the lathe too ...

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:01:58 -0700

AlexAndChristine
I don't have a file with a half inch diameter, so I thought I'd try mitering on the lathe. I also don't have a hole saw, so I did it with drill bits. The tubing is secured in the lathe too ...

Final pass with the 1/2" drill bit. It miters done this way were rough and required cleanup, I went back to just using a combo of a 12" round file and a 6" half-round file.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:02:04 -0700

AlexAndChristine
Final pass with the 1/2" drill bit. It miters done this way were rough and required cleanup, I went back to just using a combo of a 12" round file and a 6" half-round file.

Bolt support insert brazed

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:02:02 -0700

AlexAndChristine
Bolt support insert brazed

Bolt support insert filed flush with the support bar

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:02:23 -0700

AlexAndChristine
Bolt support insert filed flush with the support bar

Everything dryfit to test. There is the support bar, a pillow block (not really the right use of the term), and finally the rack tubing.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:02:33 -0700

AlexAndChristine
Everything dryfit to test. There is the support bar, a pillow block (not really the right use of the term), and finally the rack tubing.

Another photo of the dry fit pieces.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:02:46 -0700

AlexAndChristine
Another photo of the dry fit pieces.

Pillow block brazed onto the rack stay.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:02:55 -0700

AlexAndChristine
Pillow block brazed onto the rack stay.

Rack perimeter bent and brazed. It is 18" by 20".

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:03:03 -0700

AlexAndChristine
Rack perimeter bent and brazed. It is 18" by 20".

The first couple cross pieces have been brazed into the rack

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:03:53 -0700

AlexAndChristine
The first couple cross pieces have been brazed into the rack

Rack platform is complete

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:03:51 -0700

AlexAndChristine
Rack platform is complete

AlexAndChristine's photo

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:03:51 -0700

AlexAndChristine

Bolt, support bar, pillow block, and rack

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:04:24 -0700

AlexAndChristine
Bolt, support bar, pillow block, and rack

I'm making more pillow blocks. The original ones weren't quite straight and I wanted taller ones with more thread engagement.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:05:08 -0700

AlexAndChristine
I'm making more pillow blocks. The original ones weren't quite straight and I wanted taller ones with more thread engagement.

To make the pillow block I drill 5/8" steel rod with a 1/2" drill bit on the lathe

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:05:15 -0700

AlexAndChristine
To make the pillow block I drill 5/8" steel rod with a 1/2" drill bit on the lathe

AlexAndChristine's photo

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:05:22 -0700

AlexAndChristine

The hole is drilled. I'll cut the bar in half at the center of the hole, making two pillow blocks.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:05:55 -0700

AlexAndChristine
The hole is drilled. I'll cut the bar in half at the center of the hole, making two pillow blocks.

One of the pillow blocks, rough

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:05:42 -0700

AlexAndChristine
One of the pillow blocks, rough

Drilling the 5mm hole axially in the block. This will be used for the M6 mounting bolts.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:06:07 -0700

AlexAndChristine
Drilling the 5mm hole axially in the block. This will be used for the M6 mounting bolts.

Drilled and threaded for an M6 bolt. The block is 10mm tall, giving 10 threads of engagement

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:06:19 -0700

AlexAndChristine
Drilled and threaded for an M6 bolt. The block is 10mm tall, giving 10 threads of engagement

Brazing the support bar to the frame. I'll tack lightly first so that I can adjust everything to be square. This joint aligns the entire rack.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:06:26 -0700

AlexAndChristine
Brazing the support bar to the frame. I'll tack lightly first so that I can adjust everything to be square. This joint aligns the entire rack.

Tacked and aligned

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:06:45 -0700

AlexAndChristine
Tacked and aligned

Support bar is brazed and the rack is mounted from the rear. I didn't take any photos of brazing the front support bar. I brazed the front pillow blocks to the rack and brazed the support ...

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:07:08 -0700

AlexAndChristine
Support bar is brazed and the rack is mounted from the rear. I didn't take any photos of brazing the front support bar. I brazed the front pillow blocks to the rack and brazed the support ...

I switched the cable routing to run along the top tube so that none of the cables interfered with the rack. Here I'm brazing on the cable housing stop for the front derailleur. I copied th ...

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:07:27 -0700

AlexAndChristine
I switched the cable routing to run along the top tube so that none of the cables interfered with the rack. Here I'm brazing on the cable housing stop for the front derailleur. I copied th ...

The rack is done and mounted. The cable routing has also been moved to the top tube.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:07:45 -0700

AlexAndChristine
The rack is done and mounted. The cable routing has also been moved to the top tube.

Front end view

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:08:21 -0700

AlexAndChristine
Front end view

Test riding with ~40lb load (a 3.3 gallon keg full of water)

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:08:23 -0700

AlexAndChristine
Test riding with ~40lb load (a 3.3 gallon keg full of water)

I rode over to the Bike Shack carrying a donor bike (we stripped it for parts there) and a bag for my other errands. Cars gave me wide berth with this big load.

nobody@smugmug.com (AlexAndChristine) — Mon, 21 Jul 2008 10:08:55 -0700

AlexAndChristine
I rode over to the Bike Shack carrying a donor bike (we stripped it for parts there) and a bag for my other errands. Cars gave me wide berth with this big load.