44 Bikes Frame Shop

[rehoboth]

Beautiful shop! There must be great places to ride up near you. I have done a few EFTA and root66 races in NH and they have been great ( along with the 24 hours of great glen).

Have you done any 29er builds? I just built up a 2011 Epic and would love a hardtail with a 142 thru axle and a tapered steerer (copy of stumpjumper HT geo would be perfect). PM me if this is something you might want to try.

 

[fortyfour]

Ironically 29ers are my specialty:


New Setup by BLACK CAP Studio, on Flickr


New Setup by BLACK CAP Studio, on Flickr

 

[AutoXRacer]

Will there be any full suspension 29ers...?

 

[fortyfour]

Today's effort in the shop today. A bit brisk outside but the windows keep it a bit warm in there.

Tube block assembly for the seat stay mitering fixture:


Tube Blockage by BLACK CAP Studio, on Flickr

Tramming in the vise with the Starrett Last Word Indicator:


WORD. by BLACK CAP Studio, on Flickr

Few more parts and this ones done. Checking how things on the fixture set up:


Seat stay Mitering Madness by BLACK CAP Studio, on Flickr

And some vintage tool catalog love. Certified and not to be messed with:


Starrett Inspected by BLACK CAP Studio, on Flickr

 

[moto367]

44: That is a big lathe. I'm fortunate to get to attend IMTS every 2 years in Chicago. There are some big machines on display. Check this link out if you want to see really BIG! http://www.vincelewis.net/bigengine.html
Again, nice work. And when I'm in the ready for a 29'er, I may be calling you. I always felt I was too small for one but many people are telling me no. Maybe a 650?

 

[muibubbles]

bump just to keep tabs on this thread!

i was talking with my co worker last week and hes into bikes and thought about building one himself. I'm definitely going to forward him your info!

 

[kngkong]

I found this gem a while back here. Check it out if you like big machines.

However, the non-sparkle vision version would be the difference between the price of a 1960's Bridgeport and large CNC center!

Again-thanks for the kind words to all. Shop day tomorrow. Been bogged down in some design projects this past week, unexpected snow storms in October and loss of power due to 24" of snow...[/QUOTE]

Ive seen that site before. Thanks for reminding me of it. Some ridiculously large pieces of metal being moved around there.

Beautiful work in your shop. Thanks for taking the time on the photography.

 

[thk2c]

Any Updates?

 

[fortyfour]

Sorry for the tardiness as I've been slammed with design work, finishing up house projects and makin' chips! I've been thoroughly enjoying working in this space. It's not done by a long shot and there's no heat (yet...) but I'm stoked. Got my vise (Wilton) mounted up on my stand I welded a while back:



Finished the chain stay mitering fixture:



Finished the seat stay mitering fixture:



Tube Forming (These are specifically seat tubes):



And cutting tubes for a change!



Making Bikes too:



Dialing the tooling in as I go. Headed up to Vermont to a buddy's shop to use his lathe to make a few adjustments to the bottom bracket tower to accept 100mm bottom brackets. Also making some other round parts while I'm there too.

But the big update is getting things in the ceiling prepped so I can actually retain some heat. When the sun is shining, it's pretty nice inside on a cool day as long as it's mid 30's low 40's. As it dips below 35 or if the sun goes away... you better keep moving! Anyway-this past weekend I started in on the rafters. They ran them every 48" but I'd like to utilize that space at some point so I wanted to add some structure and make putting up a ceiling (Same 4x8 sheets as the walls). Then we can finish up running the electric so I can put in some permanent light. Stoked about this. Not to mention it will help retain some heat once its finished and insulation is in place. View from both directions.





I don't know how the previous owner got that window up there but it's so damned heavy I'm not even going to mess with it until I can physically get up in there and slide it out of there... But you can see how I'm supporting the rafters as I go. Just cut a pair of 2x4's and screwed them in place. Slid the 10' 2x6's up there and nail them into place.

To be continued after the holidays...

 

[Tman]

VERY NICE work! Along with hotrods I play with bicycles as well. Getting geared up to do a lugged cross bike myself. Love the building AND the bikes, I am a DIY glutton myself

 

[PeteMoore]

Still absolutely loving this workspace

Keep up the good work dude

If you fancy firing me a PM with your rates, I seriously need a couple of logos done

 

[Spam16v]

What's a frame run? Know Mickey from Spooky and Frank over in VT?

 

[fortyfour]

@ PeteMoore - I'll send you some info.

@Spam16v - I know of Frank and Spooky but do not know him/them personally. My friends shop is unrelated.

 

[Jim Johnstone]

Hey 44, nice work on the fixtures. I don't know if I missed it reading the thread, but what is your back ground as far as making the tooling goes? Are you a toolmaker/machinist etc?

 

[JimVonBaden]

You sir, have significant skills in a variety of areas worthy of making any real man jealous! Those skills, however, pale in comparison to your artistic eye!

Jim

 

[superspec]

jesus what i would give to be able to afford one of your frames, i guess ill just have to stick to the big name companies for now. your frames are damn ****! GJ group buy maybe? hahaha

 

[e-tek]

Skillz are great!
My first "good" road bike was a Vitus Carbone that I glued together myself with aluminum lugs. I used it for Triathlon racing for almost 4 years, until I was sponsored by Cannondale.

 

[fortyfour]

@Jim Johnstone: My background is pretty different I suppose. I was trained as a silversmith/goldsmith but later went back to school to get my Industrial Design Degree. Both programs were very hands on. Sketching an idea is only the first step and we were encouraged to build what we designed. So 'how' things are made is just as important as that vision of 'what' will be made. Often those moments of brilliance come out while working with the material itself and using the machines/processes to see that vision through. Aside from both programs having full machine shops/metal shops etc., I also have a natural curiosity for all things machinist so a lot of it is going to experts and having them show me the ropes. So it's a combination of training in a studio setting, tracking down the right people and having them mentor me and practice of course. The design end of things or the "eye" I think is one of those natural knacks that each of us have. I think everyone is born with a natural ability that just needs to be fostered and pursued. Constantly challenging ones faculties builds on itself.

Thanks for the kind words on the work, pics etc. It's great to be able to share with an equally enthusiastic crowd.

 

[fortyfour]

Here's the state of the shop as of late November / early December:



Too cold to paint now. I'll finish up that in the spring along with a few other details. Going to concentrate on the ceiling and making all the entryways as 'draft proof' as possible. Few more pieces I can make for the doors and jams.

 

[Jim Johnstone]

Sounds like a good program,

My background is mechanical engineering and now I'm doing a tool and die apprenticeship. Hopefully I'll get a chance to make my first custom frame next year. It's been on my list of things to do since I was a teenager.

@Jim Johnstone: My background is pretty different I suppose. I was trained as a silversmith/goldsmith but later went back to school to get my Industrial Design Degree. Both programs were very hands on. Sketching an idea is only the first step and we were encouraged to build what we designed. So 'how' things are made is just as important as that vision of 'what' will be made. Often those moments of brilliance come out while working with the material itself and using the machines/processes to see that vision through. Aside from both programs having full machine shops/metal shops etc., I also have a natural curiosity for all things machinist so a lot of it is going to experts and having them show me the ropes. So it's a combination of training in a studio setting, tracking down the right people and having them mentor me and practice of course. The design end of things or the "eye" I think is one of those natural knacks that each of us have. I think everyone is born with a natural ability that just needs to be fostered and pursued. Constantly challenging ones faculties builds on itself.

Thanks for the kind words on the work, pics etc. It's great to be able to share with an equally enthusiastic crowd.

 

[monkers]

Nice work on the shop! And your fixtures are beautiful! Thanks for sharing

 

[Spencyg]

Nice shop man. That thing is going to be a b**** to heat this winter with those open rafters! Love the old BP too. I used to run one like that and its beauty was in the simplicity of setup and making quick parts. Do you have a lathe? I see turned parts but no turning machine...

Get some insulation in that ceiling!

 

[monkers]

Maybe just staple plastic sheeting to the rafters for the winter to help keep the heat in

 

[fortyfour]

After the holidays I'm going to be installing the ceiling and insulation in the ceiling. So this is just a first step for that to happen. My efforts can be redirected again now that the house projects are finished up for this season.

A lathe is on the short list...

 

[LoRollinLS]

What you gonna do with that big window once you get it down?

 

[BeachBum2012]

You have a truly great shop and some amazing skills. I seriously need to learn to work in metal. Looks like so much fun.

 

[fortyfour]

@LoRollinLS: I have another one just like it I took out of the shop. They're yours if you want them! Once it's down though, they are either going to the recycling center or anyone who wants them. When I removed the other one which is identical in the front of the shop, I was taken aback by how heavy the darn thing was. It was one of those "OH Sh*T" moments.

This gives you a good idea of what was there:



Midway:



Pretty much done:



Reviewing these photos right now and it's quite the change. The inside alone is completely transformed. Can't wait to really button this thing up and get the walls painted in the spring...

 

[machine_punk]

I really like the organic feel of your shop. I'll bet it is an inspiring place to create you bicycle art! I am really enjoying this thread.

 

[atxgsa]

Okay I am more impressed even after two months since the last time I saw your workshop here on GJ! The images are in the pile of photos folder that I will be pulling ideas from when I finally get a chance to build my workshop /office in the next couple of years! Thanks for the inspiration!

 

[Krash Kadillak]

I've enjoyed reading your thread, 44.
One thing that struck me about the space inside was it's overall focus. When you go into a typical 'small (manufacturing) business as a customer, you might be walking up to a desk or counter. The 'shop' area is usually 'in the back', kept away from the customers for reasons of appearance, safety, or whatever. Your emphasis is on the work itself, right out front. You're not visiting a 'manufacturing company' you're visiting an artist's studio.

One suggestion that's probably already in your plans....
The building could use some kind of 'apron' around the front door and 'garage' door - perhaps interlocking stones or something like that.......

 

[MattDoves]

Looks really really nice I hope one day I'll be able to have my own

 

[kennyb52]

At awe..............A Wilton with a view......what more could a vise ask for?

 

[LoRollinLS]

@LoRollinLS: I have another one just like it I took out of the shop. They're yours if you want them! Once it's down though, they are either going to the recycling center or anyone who wants them. When I removed the other one which is identical in the front of the shop, I was taken aback by how heavy the darn thing was. It was one of those "OH Sh*T" moments.

This gives you a good idea of what was there:



Midway:



Pretty much done:



Reviewing these photos right now and it's quite the change. The inside alone is completely transformed. Can't wait to really button this thing up and get the walls painted in the spring...

Hahaha. No thanks! I have no need for them, lol.

 

[fortyfour]

@LoRollinLS: That's what I figured. So I now figure it's plan B: Throw that SOB as far as I can...

@Krash Kadillak: You hit the nail on the head. I want my clients to experience the work and craft right as they step through the door. At it's heart this is indeed a studio that will exude all things bicycles and steel. There is something planned with the abundance of granite around the shop including walkways, etc. There will also be a small garden to add some greenery / winter interest. I've also got something planned as a type of "awning" over the door too. Insulation first though. It's decided to bring winter while I was gone...

@atxgsa: Stoked to be in the pile of inspiration. That's a good place to be.

 

[Brunow]

Nice, Nice Really nice work! Way to go!
Live your dream!

 

[slimer007]

Those windows are sweet! I wanted more windows in my garage but i live to close to DA HOOD.

 

[slickgt1]

Nice work. Really love the detail on everything. Keep the pics coming.

What are you planning for heat?

 

[fortyfour]

Burning some midnight oil. 23 deg. out and still dropping tonight. Just finished up the rafters. (I'll take a pic when there is better light.) Also ordered up my ceiling material (same as the walls - 7/16" OSB) and will be delivered bright and early this friday morning. Stoked. Insulation and finishing the double set of doors on the inside will be next. Thinking about fixed propane heaters for heat. Gotta do more research and visit a shop up the road from me that uses something similar. Right now the shop's an excellent "wind block"... but that's about it!

Ventured up to Vermont to a buddy's shop to use his lathe. Had to make some round parts for my frame jig and make a few adjustments. Boring out a large spacer:



The spacer with a part to hold the new 44mm head tube standard:



And in use on the jig:



Also had to nip off 10mm from another part on the jig to accept 100mm wide bottom brackets. The relief is where the old shoulder ended:



And getting put to good use:



More soon.

 

[fergus]

Nice man! I'm always motivated when I read this thread to go out and do something...

 

[fortyfour]

Now that the light is better, shot of the rafters and improvements:



I was thinking about that window up there and the other I have and I think I may use them to break up a portion of the space by painting/hanging them from the ceiling on cables. Better than just ending up in a landfill perhaps... More on that soon.

Supplies!



OSB for the ceiling. 2x4's for the set of double doors going in next to the mill. Conduit to finish up the wiring/lighting.

Fitting the chainstays for my snow bike proto. That's four inches of fat tire clearance!






O/A setup. Victor J-28 and regs. All used (except for the lines). New to me!