Bareknuckle Brawler - Finished

[yoothgeye]

I always planned to use two stems on this bike - one on each of the fork legs with split bars.

Two stem? Hmmm...

viewtopic.php?f=55&t=39623#p386622

[gowjobs]

Cool idea, I have very little experience with threadless setups. But, if you're running the stems in the forks, how will you secure the steer tube? Doesn't the stem typically 'pull it all together'?

Cheers,
Dr. T

I'd think that a seat post clamp would work as well as a stem for that function...

[bean]

Cool idea, I have very little experience with threadless setups. But, if you're running the stems in the forks, how will you secure the steer tube? Doesn't the stem typically 'pull it all together'?

Cheers,
Dr. T

Dr. T, I'm still going to use a star nut in the steer tube. I'll just use a narrow spacer instead of the stem, and pull it all together. The top plate is also secured to the steer tube by a clamp type setup.

[bean]

I always planned to use two stems on this bike - one on each of the fork legs with split bars.

Two stem? Hmmm...

viewtopic.php?f=55&t=39623#p386622

I've always liked the two stem/split bar idea after seeing it a few years ago. European builders have been using this stem system for years. Have seen it on a number of Basman and scratch built bikes using triple trees. I've even seen pics of custom motorcycles using MTB stems and split bars.

A pic of a bike on this site from a couple of years ago

[yoothgeye]

I've always liked the two stem/split bar idea after seeing it a few years ago. European builders have been using this stem system for years. Have seen it on a number of Basman and scratch built bikes using triple trees. I've even seen pics of custom motorcycles using MTB stems and split bars.

I'll still call dibs on the idea. haha

[herr_rudolf]

The two stems on your build do fit the name you chose very well. They look like knuckles the way they're (gonna be) mounted...

[bean]

The two stems on your build do fit the name you chose very well. They look like knuckles the way they're (gonna be) mounted...

Good eye herr_rudolf, that what I'm aiming for. Guess what colour/finish they're gonna be .

[herr_rudolf]

If I think 'speed', these knuckle just have to be white!
Or... if you're getting overboard with the name/theme: a fleshy color with blood-red bolts...

I think I like em the way they are by the way... Gunmetal grey?

[bean]

If I think 'speed', these knuckle just have to be white!
Or... if you're getting overboard with the name/theme: a fleshy color with blood-red bolts...

I think I like em the way they are by the way... Gunmetal grey?

I'm not getting too wrapped up with a theme..........more of a name really. Just want a tough looking, bare metal bike that I can ride. At this stage, the stems will be bare alloy.........but anything can happen!

[herr_rudolf]

Bare alloy...
NICE!!!!! Good thinking...

[bean]

I found a matching stem adapter, just have to cut the fork tubes down and find a pair of stems. Also did a quick mock-up. I want to drop the front end a tad, and get the seat lower (maybe I'll have to join the cut down seat tube crew). I've got a couple of ideas for seat mounting.

I made a buck out of piece of hardwood I found in a scrap bin at work. I'm going to hand form a metal tank for this build and will do a bit of a how-to along the way. I still have to round off the corners on the buck and shape it a bit more. If I was making more than one tank, I'd make a pair (one for each side), but I'll just make the one for this build and flip it for the other side of the tank.





Start of the buck

[bean]

How good are quill adapters?

They can be awesome problem solvers........have used them a number of times .

[Dr. Tankenstein]

I'm definitely feeling the "Brawler" vibe.
Sweet ride so far.

Cheers,
Dr. T

[bean]

I'm a Coppersmith by trade, but have not really done any coppersmithing since 1995, so I figure it's time to test the skills.

I made a cardboard template of the space and made it around 1/8" smaller (to allow for the metal thickness when it's folded. I then cut out a hardwood blank, which is called a buck, and sanded the corners to a radius. I'm going to use the one buck for both halves of the tank.

Cut the sheet copper larger than than the buck. How wide you want the tank will determine how much bigger to cut the sheetmetal.


Notch out the corners so they will meet up when folded.


The copper has to formed to the curves of the buck, so it's better anneal it. I used oxy-acetylene, but it can be done easily with a propane torch. Heat the copper to dull red then quench it in water.



Clamp the copper to the buck leaving an even amount of the excess material all the way around and secure in a vice.


Pin (fold over the excess) in a few places to stop the copper from moving around, then remove the clamps for easier access. I used a nylon dresser, but a wooden mallet would be fine.


Fold over the excess material until it's flush with the sides of the buck, them remove from the buck.





One half of the tank is now formed. Next will be to make the other half, then trimming some material so both halves fit together well and joining together. I will probably use phos-copper brazing rod.

More to come later.

[Rockit!]

I'm curious, are you planning to strengthen the flat area in any way? Those radiuses (radii?) are nice and clean!