ECHO

Discussion in 'BUILT FROM SCRATCH' started by tjwilson, Nov 5, 2018.

  1. tjwilson

    tjwilson Pro Member

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    Handlebars

    I've been wanting to cut up existing bars and reassemble them like this for a while. Glad I finally took the time to do it. Hardest part was getting the old chrome plating off so I could polish everything to match after welding in the new extensions. Not as nice as chrome but from about five feet away not too bad.

    01preCut.jpg

    02clampAreaMod.jpg

    03extensions01.jpg

    04extensions02.jpg

    The ID between the drop bars and the BMX bars / extension pieces was a little smaller. I modified the sleeves with a length-wise cut so they'd fit.

    05gripExtend.jpg

    06gripEnds.jpg

    And after a lot of sanding and polishing.

    07polished.jpg

    08polishedDetail01.jpg

    09polishedDetail02.jpg
     
  2. tjwilson

    tjwilson Pro Member

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    First Test Ride

    Before starting the polishing on the handlebars I mounted them and the seat for a test ride. No complaints from the front spokes so, I definitely gained some confidence in lacing my own wheels. The ride is also better than any other bike I've built to date. I'm pretty excited with the results.

    01testRide.jpg
     
  3. tjwilson

    tjwilson Pro Member

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    Chain-guard

    For as much as I've modified this guard I probably should have just started from scratch! Looking at the images it might need some additional tweaking. It looks a little fat in the center to my eye right now. I have some graphics in mind that may visually change the proportions. It's something I need to sit on for a while before making a final decision. Much easier to remove material then add it.

    01chainguard.jpg

    02chainguard.jpg

    03newFront.jpg

    04weldupFront.jpg

    05weldupBack.jpg

    I needed to create some clearance for the rear wheel. I clamped the guard in a vise and bent the edge over a piece a rectangular tubing.

    06interference.jpg

    07bendingJig.jpg

    08clear.jpg

    Guard filled and smoothed. Clearance is pretty tight everywhere around it. I really need to get a few miles in with the guard mounted to check for rubbing before calling it done.

    09finishedGuard.jpg
     
  4. tjwilson

    tjwilson Pro Member

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    Bits and Pieces

    I added a small tab for the brake arm. The tab came from the same small child's bike that donated the tabs for the chain-guard.

    01brakeArmTab.jpg

    I had grown a little concerned about the strength of the rear drop-outs. Especially with the leverage that the sissy bar has at the very ends. I didn't notice any movement on my test ride but decided to go ahead and reinforce them anyway.

    02dropoutBefore01.jpg

    04dropoutAfter01.jpg
     
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  5. tjwilson

    tjwilson Pro Member

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    Kickstand

    The kickstand was liberated from a Schwinn Collegiate. I didn't document the donation process. It was gruesome, red oxide primer dust everywhere.

    01schwinnDonorKickstand.jpg

    Gorilla tape is becoming my go to for hard to clamp pieces.

    02kickstand.jpg

    03kickstand.jpg

    I tacked the stand in place, checked clearances, pulled the rear wheel and crank, and then removed the stand leg before finish welding.

    04kickstand.jpg

    05kickstand.jpg

    06kickstand.jpg
     
  6. LukeTheJoker

    LukeTheJoker Moderator

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    Really nice work happening here!
    I would encourage you to enter it for voting anyway, even without the finishing touches...
    It rides and meets the criteria...
     
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  7. furyus

    furyus

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    I would second that encouragement. You’ve got more work in the chainguard than I have in my last three bikes, and spectacular as usual (must be nice to have spectacular as your usual). The bike is a winner, especially the Collegiate bits.

    furyus
     
    Last edited: Jan 25, 2019
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  8. tjwilson

    tjwilson Pro Member

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    Thanks for the compliments and encouragement. @furyus it is hard to beat the design and quality of some good old Chicago Schwinn pieces!

    I just don't think it is close enough to being finished to enter. I've got an idea I want to try out for the shifter that won't be done in time. I think I've decided on a color too. Both of those will make a big difference in how I see it looking when done. I'll definitely keep posting progress either here or if this thread should be moved to the Builds. @LukeTheJoker please let me know if or when you think the thread should be moved.

    And speaking of the shifter...
     
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  9. tjwilson

    tjwilson Pro Member

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    Shifter Design

    I decided to try my hand at creating a shifter rather than purchasing one, mostly for the challenge of figuring out and researching how to make it work. I'm pretty sure this is similar to how most 3-speed shifters are designed. I'm planning on stops to keep the handle from moving past first or third and using a spring loaded plunger to locate second.

    Measuring Cable Travel on the Shimano Nexus 3-Speed
    I checked at the grip shifter too. Both came out at about 1/4 inch travel between gears.

    01cableTravel.jpg

    Diagram of the Shifter
    Knowing I needed 1/4" travel between gears I could design a way to pull and release the cable and determine the amount of shifter handle travel.

    02drawingShifterInPosition.jpg

    Start of Base and Shifter Handle Plates

    03shifter.jpg

    04shifter.jpg
     
  10. furyus

    furyus

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    Sarcasm, TJ. Kinda like if I said Jan is way hotter than Marsha (eye roll). Regardless, your work is fantastic.

    furyus
     
    Last edited: Jan 28, 2019
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  11. furyus

    furyus

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    Ha! And I'm over here rubbing oil onto old bike parts and calling it a "build." Your stuff is clearly a few levels above the ordinary, TJ. Holy Toledo on the diagrams, dude.

    furyus
     
  12. kingfish254

    kingfish254 CHECK OUT MY SALE THREAD FOR COOL STUFF! Pro Member

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    Wow!!! As usual, you have the classiest workmanship around man! Excellent design, execution, and mad skills! Get this beauty done!!!
     
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  13. LukeTheJoker

    LukeTheJoker Moderator

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    How about I leave it here until the build-off is done in case you change your mind? ;)

    Give me a nudge after and I will move it to builds for you!
     
  14. tjwilson

    tjwilson Pro Member

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    Well didn't make the MBBO deadline but, work continues...

    Shifter Internals

    Pieces that make up the plunger / stop for second gear. These ended up being trimmed and tweaked a number of times.
    05shifter.jpg

    06shifter.jpg

    This is the start for the handle. I plug welded a cut 3/8 inch bolt to 1/2 inch tubing.

    07handle.jpg

    All the internal pieces. This ended up being way more elaborate than I originally thought. Happened when I started with a general idea of the shape and size I wanted and then trying to fit everything into that space.

    08explodedPieces.jpg

    09detail01.jpg

    10detail02.jpg

    11detail03.jpg
     
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  15. tjwilson

    tjwilson Pro Member

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    Schwinn-ish Type Shifter Mount

    With it mounted I was able to confirm that it actually shifts the gears.

    01_backMountingPlate01.jpg

    02_backMountingPlate02.jpg

    03_mountedShifterLFT.jpg

    04_mountedShifterRT.jpg
     
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  16. The Renaissance Man

    The Renaissance Man __CERTIFIED DIVER__ (Open Water & Open Dumpster) Pro Member

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    That's what makes doing this stuff fun! It's very satisfying when you get it to work. :happy: Nice job!
     
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  17. LukeTheJoker

    LukeTheJoker Moderator

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    Nice work on that shifter!
     
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  18. toro1978

    toro1978

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    I am speechless. I bet this is everybody's favorite section of te forum. Now this is a CUSTOM all caps. Incredible!
     
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  19. furyus

    furyus

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    Love the back cover of the shifter, where it looks like the metal has been chisled away or broken off in chunks. Very unique detail. Maintaining remarkable, tj.

    furyus
     
    Last edited: Feb 12, 2019 at 8:34 AM
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  20. tjwilson

    tjwilson Pro Member

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    Thanks. Unique is one way to describe it but I think that's kinda generous ;). I've got a cover for the entire shifter in mind...
     

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