"Building a welding JIG first" - design process and thoughts

[BartRidesEternal]

All of it, just Awesome. I'll be sitting down the next few days scratching ideas for a trike frame. So id love to see some of your buddies work. That complete twin tube frame made me so happy I think I peed a little. I'll be checking out the links all week and following this closely, with great interest, inspiration and a bit of awe. Thanks.

My buddy worked as a welder on these:

A highly skilled company building frames, gearboxes and more.



M20 in my JIG!

 

[Ed Stately]

That's very impressive. And all I'm attempting is to make something a bit bigger and with more style then this as a reference frame. Infact I just sat down from gathering up some old conduit and PVC pipes and some scrap flat bars to put together a mock-up of what I want to do before I start chopping up old bike frames. I'm really glad I don't get threatened or overwhelmed when see a masterpiece and thinking " couldn't pull that off.". Lol. I'm confident that with material available and a clear sense of my own limited knowledge and ability that I'll do just fine for a 1st bicycle fabrication or rearrangement. His and your work are inspiring and I've already picked up on a couple things to look out for that had not accured to me. Thanks again.

This is the frame I'm using as a sort of reference. It's a small 1976 24" trike.

 

[BartRidesEternal]

That's very impressive. And all I'm attempting is to make something a bit bigger and with more style then this as a reference frame. Infact I just sat down from gathering up some old conduit and PVC pipes and some scrap flat bars to put together a mock-up of what I want to do before I start chopping up old bike frames. I'm really glad I don't get threatened or overwhelmed when see a masterpiece and thinking " couldn't pull that off.". Lol. I'm confident that with material available and a clear sense of my own limited knowledge and ability that I'll do just fine for a 1st bicycle fabrication or rearrangement. His and your work are inspiring and I've already picked up on a couple things to look out for that had not accured to me. Thanks again.

This is the frame I'm using as a sort of reference. It's a small 1976 24" trike. View attachment 265489

Very cool frame Ed!

Thank you, I really appreciate your reply.

@kingfish254 showed a picture here from a bicycle called 'Stardust'. I instantly thought how did he do that? Tight bends, alignment... skills!

Regarding your frame:
You could utilize the front part of a larger bike and build the rear. Alignment from the bottom bracket rearward.

Or use a standard frame and just add that big diameter rear tube including the trike dropouts.

So many ways to build

 

[Ed Stately]

Very cool frame Ed!

Thank you, I really appreciate your reply.

@kingfish254 showed a picture here from a bicycle called 'Stardust'. I instantly thought how did he do that? Tight bends, alignment... skills!

Regarding your frame:
You could utilize the front part of a larger bike and build the rear. Alignment from the bottom bracket rearward.

Or use a standard frame and just add that big diameter rear tube including the trike dropouts.

So many ways to build

As of now I've settled on using that frame.just for reference. After all it is a 48 year old single year design bike and other then the rims and spokes I still have everything for it. And I think it will go smoother and have a cleaner finish built from scratch rather than chopping this up and changing it. I can't draw to save my life so I made a giant sized tinker toy style mock-up so I could see how it looked not in my mind. I'm making the wheel base about a foot shorter and decided on a step up king and queen motorcycle seat. Over all I'm satisfied with the rough draft.

The picture below shows how I plan on 2 bikes top bars then welded onto the side of the head tube and the bottom bars will come together at the back of the bottom bracket and the single tube straight up the the bottom of the head tube. The outside rear stays I'll keep , bend and possibly lengthen. Still have a couple other ideas for that . Looking at a heavier then stock 40-44 inch wide rear differential and axels.

 

[Ed Stately]

Very cool frame Ed!

Thank you, I really appreciate your reply.

@kingfish254 showed a picture here from a bicycle called 'Stardust'. I instantly thought how did he do that? Tight bends, alignment... skills!

Regarding your frame:
You could utilize the front part of a larger bike and build the rear. Alignment from the bottom bracket rearward.

Or use a standard frame and just add that big diameter rear tube including the trike dropouts.

So many ways to build

I'm also working out in my head the best way to get some type of rear suspension, my brain is thinking small air bags and possibly adding spindles and u-joints to the axels so I can have some camber for higher speeds when I break down later and add that 3000w electric motor to it. A neighbor already brought over a 10hp horizontal shaft Tecumseh motor last night.

 

[BartRidesEternal]

I'm also working out in my head the best way to get some type of rear suspension, my brain is thinking small air bags and possibly adding spindles and u-joints to the axels so I can have some camber for higher speeds when I break down later and add that 3000w electric motor to it. A neighbor already brought over a 10hp horizontal shaft Tecumseh motor last night.

Or this:

 

[BartRidesEternal]

Some updates:

I ordered and designed all remaining parts for the JIG.

• I will use a standard M10 threaded rod for the rear dropout. Or a Shimano CB-E110 shaft (M10x1 threads).
• Cones for the seattube and headtube are in!
• Angular profile (50x50x10) for the top seat tube is ordered.
• Tube clamp for the seat tube near the bottom bracket:

The idea is to clamp it with a simple glueing clamp. Strong, tight grip and enough elasticity to retain that grip over time.
The orange rounds on the photo are tube diameters similated. 25mm and 45mm thickness variables.
Its a 10mm thick 6062 aluminium angle profile.

 

[BartRidesEternal]

In regards to building my own designed frames in the JIG: I had a little luck yesterday. A guy on a online marketplace was selling brand new, and complete shaft drives for less than 1/10 of the original price.

The box with five complete sets.

Dropout on the left. Bottom Bracket on the right, complete with locknut, square tapered shaft and locknut.

Two pictures above: threaded sprocket.

Pictures above: Three slotted sprocket.

The larger diameter is nearly the same as a US bottom bracket pot. Awesome!

Options and ideas!

 

[SkyknightJohn]

Nice find. I’ve never found those for sale except for production levels. The hard part might be finding compatible hubs, which I also have not had success.

But if I understand, the threaded/splined sprockets inteface with the drive gear on one side and the threaded hub/three-splined IGH on the other? No wonder I failed! lol.

Should be able to make a bomb proof, low maintenance cruiser or town bike. No chain to dirty the dockers!

 

[MattiThundrrr]

I had a little luck yesterday. A guy on a online marketplace was selling brand new, and complete shaft drives for less than 1/10 of the original price.

Congrats, man! That's a great deal! Can't wait to see what comes out of elBarto's shop next!