44 Bikes Frame Shop

[ODIS]

Have thoroughly enjoyed your thread. Learned about the fabrication process on the bikes, tables, work-flow and shop. Have to believe that your family has shown patients for all the time you have spent building this business and are appreciative for your tenacity and talent.

Thanks for all of the efforts in creating this thread and for all the ancillary links for more information on your labors in this life.

Ody.

 

[bknudtsen]

Well, there's 4 hours out of my life that I'll never get back...



Totally worth it!!!! Bravo! The shot of the workshop in the snow with its bright blue doors and time worn barn wood is absolutely magical. Saved it to my favorites for inspiration.

Regards,

Brad

P.S. More snow shots would be greatly appreciated!

 

[fortyfour]

Recently finished one of two bikes headed to Switzerland. Was really happy with how it turned out and figured it was a good candidate to take some more "studio" type shots. Here's my setup down in the "Bike Dojo". I had to move 2 bikes (not pictured) to make room for the lights. But you get the idea.

So this...



Gave me these two shots amongst a few other detail shots:





Also recently finished up a fat bike headed to Switzerland too (to give you an idea, that rear tire is about 4.5" in width aka BIG):







Simple way of holding a braze-on in place while brazing:

 

[A1an]

Amazing work as usual.

 

[abstamaria]

Again let me say, extraordinarily beautiful photographs, Fortyfour.

Andy

 

[blairjw]

I was just checkout out your site during lunch today, then tonight, I added my barn to the index... then sorted on NH and... Hi Neighbor, I am in Peterborough.

I have a buddy with a cracked frame on a gas gas (trials bike) they are crome moly... do you do any repairs on motorcycles?

Blair

 

[VMX42]

Great work Kristofer,
Looking forward to more updates in 2013.
Thanks from DownUnder...
Jeff

 

[thinkracing]

I've enjoyed following this thread. I bike some, but appreciate more the craftsmanship and care that goes into each of your creations.

Great work.

 

[YoungMedic]

This thread continues to deliver! A joy to follow

Any update on another round of shirts?

 

[fortyfour]

Thanks to all for the kind words. Today I met with a local outfit to assess getting a heat source in the shop: Rinnai. Suggested either the ES38 or the EX22. There's only a $400 difference but I'm doing some research on what I really need for the space. For my zone it appears that 50-60 BTU's / sq-ft is about right so perhaps the ES38 is the ticket. Will think on it over the weekend. Finished up a singlespeed 29er that will be headed to Arizona:







And built up:







We've been getting some snow too so that means the FAT BIKE gets busted out!





@Blairjw: Hello to you as well. I'd be happy to take a look a the moto to see what's doing - you'd have to bring the frame over to the shop however if it's possible. If you are ever in this neck of the woods, give me a shout - be happy to show you the shop.

To all who are interested in a T-Shirt, I will be doing a new run in the new year sometime end of perhaps January or early February. I will let everyone know what the design will be and pricing for those who have been interested.

Oh, and here's the frame as I'm shooting it :

 

[CrustyD3mon]

What an amazing work....

 

[superspec]

let me know when the demo bike is ready to ship! I'm itching to ride one of your frames!

 

[Omphaloskeptic]

FAT BIKE looks right at home out there in that 'white stuff'! Just curious, has anyone ever created chains/cables for biking in the deep snow, or maybe even ginned-up a sprung front with a 'steering ski'?

Its just got to make you feel really ALIVE to be out there huffing and puffing that cold crisp winter air in that beautiful countryside.

 

[superspec]

I was huffing and puffing some cold crisp air this past Sat in a 6 hour race and the last thing I felt was ALIVE.

 

[fortyfour]

In a race perhaps not but for pleasure and adventure, certainly yes I would say I've never felt more alive while on a bike, in the woods, ripping trail. Now take that same scenario, cover the trails in fresh powder and give yourself some fat tires and it's equally amazing. The forest takes on a whole different look and feel. Some shots from this past weekend on singletrack that was packed just right:


Trails were packed! by 44 Bikes, on Flickr


Let's ride some trails... by 44 Bikes, on Flickr

 

[Sunbimmer]

I'm not into bikes at all, but I love the work you're doing and your passion for what you're doing.

Nice place you got there.

 

[jesperjes]

FAT BIKE looks right at home out there in that 'white stuff'! Just curious, has anyone ever created chains/cables for biking in the deep snow, or maybe even ginned-up a sprung front with a 'steering ski'?

Its just got to make you feel really ALIVE to be out there huffing and puffing that cold crisp winter air in that beautiful countryside.

Do you mean something like this:
http://www.engadget.com/2006/12/17/the-ktrak-half-ski-half-track-mountain-bike/

JJ

 

[fortyfour]

Let's bring in some HEAT

So after a cold as hell couple of weeks up here, I pulled the trigger on a Rinnai ES38. The good folks at Sanford Temperature Control in Milford NH did the work for me. Since there was gas involved, I just wanted to get it all right and let some pro's handle the setup. The propane tank will be delivered this Monday and everything should be tested and rolling by Tuesday.

ES38 - On a temporary "stand". The shop sits up against a hill, so the vent had to be raised to meet the spec, which of course raised the heater. This is where I'll make the shelf and integrated stand to bring it up. Not ideal but it's what we had to work around:



Also took delivery of some insulation to finish the ceiling of the shop. Things should be nice and toasty. Take that Old Man Winter...



The addition of the Rinnai ES38 propane heater which was installed friday threw a bit of a visual "monkey wrench" into the shop setup. I was going to reorganize things once the floor is re-poured but the addition of the heater quickened that pace. So first things first: Move the mill forward so I can rotate it.



Once that was out in a more manageable space, I lowered it back onto the floor, and began walking the front and back so the mill rotated in place pointing it towards it's final spot in the corner of the North facing wall:



I've found picking the mill up a bit easier if you place a 4x4 beneath the ram, centered and placing a jack beneath that 4x4 to carefully tip the mill up far enough to place blocks beneath the base. Then I repeat this in front but with the tanker bar which enables me to place the 1/2" pipe beneath the mill. Repeat the process to lower it back down onto the pipes to roll. Slow and steady is the key.

Final resting spot:



The tooling cart is temporarily in front of the heater. I'm going to build a shelf around the heater, but not in front of the heater to make it a bit more visually integrated with the shop space. This will be a nice spot for tooling and right next to the mill. The future lathe will sit to the right of the heater, so tooling and heat will be right at hand.





Whole move took about 6 hours with the majority of the move being the mill due to the uneven floor. It was slow going moving it a little bit at a time. Going to insulate the ceiling this afternoon so the new heat which will be online monday will be fully retained and I'll be nice and cozy.

And of course, just a few shots of this past weeks work:









Enjoy. Till next time!

 

[Omphaloskeptic]

fortyfour, you'll be snug as a bug in a rug in no time; betcha can't wait. I can't recall if you caulked the seams in the ceiling OSB, but that would help keep your space nice and tight to keep that precious (and expensive) heat in.

You have a good amount of glass in your shop walls; any thoughts of creating storm windows for that expanse? I've used those indoor kits (heat shrink plastic w/double stick tape), and even in my mild winter climate, they really help keep the drafts and heat bill in check. I know you are eventually going to replace the floor and I was wondering if in your frigid climate, it makes sense to lay down insulation before the pour? Maybe these ideas are overkill, but wouldn't it be nice to be able to work in shirtsleeves in February? lol

 

[fortyfour]

Today's Effort : Insulation-pocalypse

Holy cow was THAT a job. Crawling on all fours, balancing, face first into small tight spaces, shimmy here, shimmy there... I'm really glad I waited till the winter to do that job. I was sweating and it was cold out! If I never see pink insulation again it will be too soon. Now I know when friends who have done insulation and said "That totally SUCKED" I can fully appreciate and relate. But the good news is that the shop is officially ready to take on "Old Man Winter" with a vengeance. Naturally, and just my luck, it's 44 Degree's out right now and rising... Good number at least!

All done :



Aftermath :



I have exactly one beer left in the refrigerator. It tastes OH so good right now.

@Omphaloskeptic: The windows are double paned and foamed in along with all 4 walls having 3.5" yellow foam which is also spray foamed in. I did not caulk in the ceiling but just finished insulating it with R-30 insulation this afternoon. The floor will be insulated and reinforced when the time comes for sure. In my climate, it's important to insulate, and maintain a constant temperature without too much temp. swing. I think now that the entire space is insulated and sealed relatively tight, it will be much better.

 

[machine_punk]

Cool! errr...warm! I doesn't get very cold here in Napa Valley, but I have lived in VERY cold places. I'll bet you are really looking forward to heat.

I saw a lot of Rinnai appliances when I lived in Japan. They are a well-established company and I'm sure you will be satisfied with that heater. I was looking into Rinnai equipment when I wanted to build a portable catering cabinet (they build cook tops and stuff too).

Kev

 

[flippin]

Scary talented on so many fronts!!! The list of what impressed me continued to increase as I read through the posts. Frame design, geometry, execution, branding are incredible. I really appreciate your passion and desire to control every facet. It was great to see all of the Park Tools again. 20 years and 30 pounds ago I worked in the industry and raced road, x-country and cyclo-cross. That said other than the Park Stand and the stay/fork alignment tool I didn't recognize anything. I guess keeping all of my tools with the intent of building my sons bikes/wheels is a bit funny in retrospect (they're only 6 & 8 lol) I'll have to post some of the dinosaur tools that we used back in the day. Do you even know what a fixed cup tool is

From a history perspective not too far from you in Sommerville Mass, there was a relatively famous bike builder that I raced for in the 80's. I'll let you guess.

Again thank you so much for taking the time to share your incredible world. I am so envious of the life that you made by hand one day at a time!!

-Paul

 

[Corvette Joe]

Im very impressed. Like what you did to the old building-great vision. Wish you were my neighbor.

 

[fortyfour]

In recent news: 65 in the shop and only need one layer to protect me from the death rays...


Welding Beezy's 650b by 44 Bikes, on Flickr


Welding by 44 Bikes, on Flickr


Seat Tube Weldery by 44 Bikes, on Flickr


Head Tube Welds by 44 Bikes, on Flickr

 

[4th-stooge]

An admirably steady hand combined with a carefully calibrated eye.....

Very beautiful welds result!

 

[DelayedZ]

Your welds are ****...I have no other words to describe it, lol.

 

[crawler07]

let me start off by saying thanks for posting this build here. Your an exceptional artist with a crystal clear vision for what you want. Your bikes are built with such detail and high level of quality you just dont seem to overlook a thing. Im an aspiring welder as well im learing to tig weld and the argon gas is flowing fast. i have a welding question if you dont mind, Do you back purge the tubing as you weld it? i see alot of people do it and some dont i guess the idea is to have good gas coverage all around the welds including the back side whae you purge the tubing. Oh and those fat tire bikes are friggin awesome!!!!

 

[zmaxmotorsports]

Nice welding

 

[56rpm]

Hey Kris, I haven't stopped by here in awhile. Looks like you're still quite busy. I sure do like your welding fixtures. Have you ever just cleared the bare frame so the world can see your beautiful welds and the colors near the welds from the tig?

 

[fortyfour]

@crawler07: For 4130 and Chromoly Steel tubing it's not necessary to back purge (you can, but it's not essential from what I understand). For stainless and titanium it is and I do back purge. If you are just starting out, an important point to make with good gas coverage is first setting the correct CFM (I'm running between 10-15 CFM). The next tip is to use a gas lens. I'd recommend a No. 8 cup, the shorter stubby style actually, with a matching gas lens. This is better than the stock collets as it evenly distributes the argon over the weld site and cuts down on what they refer to as turbulence which can effect your arc. Also use lanthanated tungsten (non-radioactive). This one has a gold tip as opposed to the red tip in thoriated. My setup is a No. 8 cup, gas lens with 1/16" lanthanated tungsten. This is good for detailed work. For heavier duty work, 1/8" is better but I know some builders have been using 3/32 tungsten tips too (I don't know how they're getting into tight spaces with those... I have enough trouble with 1/16"!):

@56rpm: There are some treatments for clearing steel with powder which are interesting but the rub is even a finger print will eventually rust beneath the clear. That's why we have titanium I suppose. No paint needed there and I'm in the process and getting my setup dialed...

Some work from yesterday:


Tacking by 44 Bikes, on Flickr


Weldery for the Beezery by 44 Bikes, on Flickr


Tacked and Welded by 44 Bikes, on Flickr


Beezy's Seatstays by 44 Bikes, on Flickr

 

[Mikej1]

44 - Are you going to NAHBS?

 

[MSD Shop]

The care and passion in this shop is a pleasure to see. I think this country has lost some of its roots of hard work and down right determination. Nice to see that again. Your shop and your bikes are truly inspirational.

 

[fortyfour]

@Mikej1: Unfortunately not this year. I would like to go but it's not in the budget this year. If it comes next year closer to the east coast, or is on the east coast, I will be there in 2014. Even regardless of where it is I may just have to go! It's time...

So with the recent snow melt, it's time to build up the singlespeed and go get some:


Rock Gardening by 44 Bikes, on Flickr


Yep... That's my little sweetheart. by 44 Bikes, on Flickr


Climbing by 44 Bikes, on Flickr


If you only can have one... by 44 Bikes, on Flickr

 

[Mikej1]

Saw your place on cabinporn!

 

[fortyfour]

Been busy making some new tooling:













And getting ready to build up this fat bike. Tires are due in around mid february:







And if anyone ever asks you... (If anyone wants this to print, let me know and I'll get you a pdf or jpg).

 

[ckadams00]

Kristofer - been lurking here for pages and pages and pages. You are probably under 10 feet of snot this weekend, hope you are staying safe and warm. Do you ever sell these frames and if so where/how? I have an old 1991 Klein frame that was my last love - time to upgrade to something new and - like Klein (I lived in Seattle and knew the guys in Chehalis) I prefer to know the guy who did the welds on my bikes. Cheers.

Duh, should have clicked through your links. Nevermind!

 

[monkers]

great shop, and beautiful work on your tooling and bikes, awesome welds!!

 

[atxgsa]

Love the color wheel sign! That is great!

 

[AussieDan]

New jig looks interesting, guessing it's for mitering where the upper stays meet the seat tube.

What program are you using to produce your drawings? They look great too!

Oh yeah, the color wheel rocks!

 

[fortyfour]

@AussieDan: For tooling drawings and specs I generally use a combination of Solidworks and of all things Adobe Illustrator. I have a plugin for Illustrator that allows you to do dimensional drawings. So for some things that are very simple, I just draft a planned view drawing in Illustrator as it's quicker for me sometimes. For more complex assemblies, I use Solidworks. For all the graphics, I'll do quick hand sketches to work out the ideas and then I use Adobe Illustrator to formalize the designs and all the layout work for catalogs and such I use Adobe Indesign.

And yes, the larger jig is for seat stays. There's some placeholder "hardware" in place for the photo. I have some locking handles, knobs and appropriate length shoulder bolts on their way for the assembly from McMaster this week once it decides to stop snowing...


23" and still falling by 44 Bikes, on Flickr