44 Bikes Frame Shop

[dogadileman]

Nope. 44 as in 44 is my lucky number. I leave space on the seat tube badge for customers to have their own personal lucky number stamped/engraved.

You had said you were originally based in Providence. I thought it was a reference to RI 44. Cool that it's your lucky number though. Mine is 37. I'll take a bike with that on it. If only I could afford it!

 

[Stuntmonkey]

Wow, amazing work. I love your welds, pure visual awesomeness.

 

[kgorman]

W o w

 

[fortyfour]

44 Bikes Frame Shop Update 9/19/2011

Short update for everyone. Just a reminder, here's where I started last fall:


Shop - Front by BLACK CAP Studio, on Flickr

Along with the shop buildout we're also tackling painting/staining/installing windows in our house this past summer. So saturday was paint windows in the house and sunday was devoted to shop time. I spent the better half of the afternoon hanging the carriage doors. I had run some errands on saturday and picked up the insulation for the doors of which I just didn't feel right about putting on top of my car, so I took the measurements along with me and just cut them up in the parking lot. I got some curious looks from customers. Back home I installed the insulation parts, foamed it up and sealed everything up Saturday evening in the dark.

So sunday I started in the afternoon hanging the doors after installing some freshly painted windows back into our house. Kind of a warm up - get the juices flowing and do something right. Later down at the shop, I stood the first one up into position and as soon as I got it in the entry way I knew it along with it's twin were just a hair too wide. Along the way I had reconfigured the entry way and beefed things up a bit by removing some trim and adding a second 1x6 effectively adding about a .25" to both sides of the entry way. I had left myself some wiggle room but I guess just not enough wiggle. A bit disheartening at first. So far this whole project has gone down without a hitch. I figure I've met my self allotted 1 and only "Ahhh Sh!t" quota for this project with this one. So out came the circular saw and I trimmed off about a .50" from one of the doors. First Cut:


First Trim by BLACK CAP Studio, on Flickr

I'll be adding a strip down the edge of this door to create an overlapped edge to seal off any air. I'll plane the edge, sand and repaint. Once that was complete and I was through kicking myself, I hung the second door and got things leveled up. Here's a shot from the outside of the finished doors:


In-swing Carriage Doors Hung by BLACK CAP Studio, on Flickr

I really like how the subtle keystone over the entry way plays with the arc of the doors. Let's take a giant step back and look at the whole kit coming together:


Shop Front by BLACK CAP Studio, on Flickr

And one from the inside:


Shop doors - backside by BLACK CAP Studio, on Flickr

I used strap hinges that are the lift off pintle style. I'm pleased with the way fit/finish of the hinges made by National. Made in the USA too which is a bonus.

Later this week I'll be getting the remaining hardware for the inside of the door. I'll most likely put up all the trim over lunch today/tomorrow for the entry way. Thanks for looking!

 

[TONE]

Wow! I love that blue. Looks amazing, and nice fab work on the doors.

 

[rickairmedic]

I agree the doors look great and the color works well with the siding on the building.


Rick

 

[tinbender 66]

I have to quit for the night at the end of page 3 but I'm mightily impressed so far!!! I'll catch up tomorrow.

 

[fergus]

Re: 44 Bikes Frame Shop :: Update 9.13.2011

Just a quick update. Got the first coat done for the doors over lunch today:


Behr: "Brilliant Blue" by BLACK CAP Studio, on Flickr

I think I need a phase converter just for the color. I'm pretty happy with how these are turning out. Scored the hardware too which is good. I'll post up pics of that when I have a chance. More soon. Also received all the goodies to wire up the Bridgeport properly. Can't wait. I'm getting darn close to "Go Time"...

Yeah...I think I'm gonna have to steal that line about the phase converter...

Hey, I'm impressed with the progress so far...showing old shops some love is near and dear to my heart. Keep it up!

 

[fortyfour]

44 Bikes Frame Shop :: Update 9.21.2011

Decided to take this morning to move the mill. I had put her up on 1" blocks last week in preparation for the move. Inverted the head and supported it with the table. Here's a shot just before I took the blocks out and lowered her down onto the schedule 40 pipe:


Ready for Liftoff... by BLACK CAP Studio, on Flickr

I cut a pair of blocks at 50 deg's to be used as stops in case things got away from me or just so I know not to push any further. It went relatively smooth and quick. About an hour of just carefully moving along and adjusting things left or right with my tanker bar:


And we have lift off. by BLACK CAP Studio, on Flickr

Here's a split shot of getting the machine onto another bar to the left and picking up the back end as it's backed up in a corner so I can get everything as level as I can. I'm going to invest in a set of machine leveling feet for sure - my floor is ridiculous. The shot to the right shows how I picked up the back end. 4x4 and a truck jack ratchet strapped to the machine just under the backside of the ram. 3 points equal a plane and I only needed to pick it up a 1/2 inch. I was pleased with how this worked out:


Rockin'. Rollin'. by BLACK CAP Studio, on Flickr

My buddy and I wired up the Bridgeport the other day and ran into a start issue. Sometimes it would just start up right away, others it wouldn't or would hesitate. Through process of elimination we narrowed it down to the switch. It has been sitting for a long time so I was anticipating something like this. Upon closer inspection of the drum switch the contacts were all but completely corroded over. Not much copper showing! So I took everything apart, cleaned all the contacts really well with 600 grit and reassembled everything.

So after all was set, I rotated the head and plugged her in. Cleaned everything up and wanted to see how my switch turned out. Plugged her in, got a big grin of anticipation and flipped the switch. Nothing. That's when it dawned on me: "That's what I forgot last night at the store: a pair of 30 amp fuses..." I wrangled a set quickly, got them in place and threw the switch again. Fired right up. Tried a whole bunch of scenario's: Still fired right up! I believe I got that one figured out.

This friday the rest of the tooling begins in ernest. It's officially GO TIME.

 

[rickairmedic]

44 that is one of those tools I would love to have in my shop . The problem is this shop isnt big enough for a full sized bridgeport . I will eventually find a benchtop older bridgeport style machine.


Rick

 

[fortyfour]

It's the literal heart of my shop. I don't know what I would do without it. I'll be adding a small tooling room lathe to my shop at some point. Something in size like a SB Heavy 10. Round parts are nice to make too. Not that you can't on a Bridgeport. A lathe is a beautiful thing.

-Kris

 

[Aggro Bikes]

Damn! I appreciate the work space, but the frames you posted up at the beginning of this thread absolutely rock my world! It's funny how different interests collide here sometimes on Garagejournal. I raced BMX forever and still own a shop, race team, etc. I can't race anymore due to too many concussions, but I've been thinking of a new XC rig just to fart around on. Might have to hit you up.

 

[Skaal-tel 79]

Love the shop. That pic of the blue doors with the little windows over top cracked me up! Looks like a huge face either grinning or scowling, I don't know.

Looks like good work, you should be proud

 

[rickairmedic]

It's the literal heart of my shop. I don't know what I would do without it. I'll be adding a small tooling room lathe to my shop at some point. Something in size like a SB Heavy 10. Round parts are nice to make too. Not that you can't on a Bridgeport. A lathe is a beautiful thing.

-Kris

Oh I do enjoy having a lathe . However a lathe cant duplicate itself which a bridgeport can .


Rick

 

[fortyfour]

HA! The doors and windows have that "Blue Monster" feel... Keeps things fun. A bunch of barns around these parts have long windows over the big doors and I was mimicking that look a bit. I may change them out at some point and add windows to the doors. I'm noticing they don't actually let much light in ironically! Build and learn.

Glad to hear people are digging how this is coming together. It's been a mountain of work and very gratifying finishing just a part of it and standing back to see how things are progressing.

But I have to say, after sitting on that Bridgeport for close to 5 years... to get power down to the shop, then finally wire it and turn that switch. That was nothing but wide eyes and white teeth.

 

[Rezarf]

Your place looks great bro. As an ID myself, you have a great eye for detail bud. Keep it up.

 

[fortyfour]

Shop Forward Progress ...and in Reverse Progress

Going Forward: Mill is in place and I'm able to work finally. Nice little moment here: drilling/tapping the first hole on my Bridgeport:


First tap by BLACK CAP Studio, on Flickr

It's may be a small step but it was incredibly satisfying to be able to finally work with my own two hands on something real and tangible. Squaring up the ends for a piece of tooling:


Start Here. by BLACK CAP Studio, on Flickr

And now we're in Reverse: Been having a few start issues with the Bridgeport occasionally so I ventured down to the shop today at lunch to try something that a friend had recommended. Sure enough what he recommended worked and the start issue is gone. I clean up to head back up to the studio to keep working and turn around to this gem:


Moose "Wrastling"... by BLACK CAP Studio, on Flickr

I first saw it from the inside, the above sequence is from the outside. The far left window was smashed. Just the external pane of the double pane window. At first I thought if something shifted in the building or if something flew into it like a rock. Upon closer inspection the plants in front of the window are completely trampled and there are pretty deep scratches in the trim work, and board and baton's. Looking around the plants I discovered large hoof prints which look very close to a Moose print. Tough to tell by this shot:


When Moose Attack by BLACK CAP Studio, on Flickr

But there are many and they are almost spot on to what a moose print looks like. They've been doing some logging across the street deep in the woods and I wonder if this one may have been spooked early this morning or was "just walking by" late last night/early in the morning. It may have been spooked by it's reflection or just whacked the window with it's rack. Either way, it's about 250 bones to replace. One step forward, and 2 steps back. I'll have to post a sign and see if I can 'wrastle' that ****** for who pays...

 

[smsteve]

Holy ****! How many people can say their garage was attacked by a Moose?

Still really enjoying the build, keep those pictures coming. Even if just to show off what hops off the Bridgeport. I'm interested!

 

[Omphaloskeptic]

Did you happen to see any 'flying squirrel' tracks out there? LOL

 

[fortyfour]

The squirrels know better. We do get the occasional "misguided" bird up at the house. We had a hawk completely knock himself out and come too on the north side of our house last year. One moment I have to laugh about it. And in another I'd like to 'wrastle' that darn Moose...

 

[rogsmart]

Most guys just complain about random vandalism from kids or some A hole trying to break into their shop. I gotta say a moose rack through the window is a real WTF moment.

The shop is quite an accomplishment especially considering where it started out from. Real nice photo work to document it as well. Thanks so much for sharing it with us.

 

[fortyfour]

44 Bikes Shop Update - 9.30.2011

Just a self portrait. The shops not finished but this is pure stoke for me. Finally working at my mill:


Workin' at the mill by BLACK CAP Studio, on Flickr

Finished up my way covers. Simple function:


Way Covers by BLACK CAP Studio, on Flickr

Small parts can be the most fun to make:


Hold down perch by BLACK CAP Studio, on Flickr

Today's work finished:


Dummy Business by BLACK CAP Studio, on Flickr

I'm a happy man.

 

[JMcFly]

Magnificent.

 

[c/o say]

Hey will insurance cover moose damage. Damm glad we don't have them running around here the deer are hard enuff on cars I don't need to have a moose running into the shop. The mill looks nice and handy.

 

[Bib Overalls]

The picture of you working at the mill is artful. Worthy of a frame.

 

[thk2c]

without a doubt my favorite garage thread. keep up the good work!

 

[fortyfour]

Shop Update 10/2/2011

Finished up the door late last night. Ended up having to do a little bit of trimming. Seems like a theme:


Door Hung finally by BLACK CAP Studio, on Flickr

I've been hauling this piece of lumber around with me for close to 10 years. It's scrap from the piers/board walk when they reclaimed the water front in front of the I.D. building in Providence. Had a small check in it so I made a bow-tie to keep things tight (little wet out, it's been raining to beat the band):


Bow Tie by BLACK CAP Studio, on Flickr

Let's step back and see how things are coming together. Added another keystone over the door and added a small walk way in front. I have so much scrap wood left over from dismantling the horse stalls. Seems appropriate to use this stuff up!


Shop Status: 10/2/2011 by BLACK CAP Studio, on Flickr

Once that was done it was time to clean up and get to work on the mill. Burning some midnight oil on a tacking jig. This is part of a sub-assembly to hold and register different bottom bracket widths. Lot's more to be finished on this:


BBHD: Bottom Bracket Holding Device... by BLACK CAP Studio, on Flickr

Mock-up of the tacking jig:


BB Assembly Tacking Jig by BLACK CAP Studio, on Flickr

That's it for this weekend. Going to start again bright and early tomorrow. Moose be damned...

 

[-Brent-]

Super job, FortyFour. I really enjoy the build... your photos rule too.

 

[White Trash Renegade]

Absolutely Amazing!!!!!! I love that shop!

 

[fergus]

Man...if you keep this up...I may actually get off my duff and go do something to my own garage.

 

[felixgogo]

I reckon this is one the best workshops on here, and a perfect size too. Not to big, not too small!

I really rate it - well done that man!

 

[Jim Johnstone]

Gorgeous garage and frame building setup you have there. I've worked in bikes shops off and on for 10 years, and building a custom frame is high on my list of things to try.

Excellent inspiration to get some stuff done around my garage!

Jim

 

[tinbender 66]

That is such a cool place!! I have dreams about a Bridgeport.

 

[tinbender 66]

And. Nice photography too!!!

 

[fortyfour]

Fortyfour Metal Shop

Like the sign says:


METAL SHOP by BLACK CAP Studio, on Flickr

Thanks to all for the kind words. This has been a long standing dream of mine to have my own shop. It's very fulfilling to walk down my lane to a space and do what you were meant to do.

 

[fortyfour]

Putting hands to work

Today's effort:


Bottom Bracket Assembly by BLACK CAP Studio, on Flickr

And a new arrival to the shop last week. Northern Industrial TIG cart. For the price, it's very well made and I'm impressed to say the least with it's construction. I wanted something small to put my accessories, helmet, gloves etc. and this one fit the bill with two smooth sliding drawers:


Welding Cart by BLACK CAP Studio, on Flickr

 

[LoanRebel]

awesome fab work

 

[sikopal]

Amazing to see such progress in such a short time.
KB's shop in Santa Cruz never looked so good!

 

[HotShoe]

Simply awesome.

You have an excellent sense of design that makes even the most mundane topics seem artful. I really love all the graphic touches and I'm raging jealous over the Bridgeport but more so the beautiful structure within which it resides.

At least some day I might find a decent Bridgeport in my neck of the woods. Moving it is a different story!

Congrats on an incredible space and best of luck with the bikes.

 

[fortyfour]

New Addition

New to me Kurt D60. Picked it up used and at a good price:


Kurt D60 Vise by BLACK CAP Studio, on Flickr

The other vise "looked" nice after I painted it and put some time into it but honestly it was still a mess and not worth more time. There was a reason why it was given to me free of charge when I purchased the mill. I'll most likely find some sort of use for it. Boat anchor comes to mind. Door stop. The shop "enforcer'. Moose munitions...