44 Bikes Frame Shop

[sbhockey]

Not sure if it's been asked before, but if you have the choice of spending the day riding or building which do you prefer? There are definetly days when I have more fun building my track motorcycle then riding it. Not always, but some days for sure.

 

[Zeke]

Post #921 should be a chapter in the Business Bible.

 

[fortyfour]

Not sure if it's been asked before, but if you have the choice of spending the day riding or building which do you prefer? There are definetly days when I have more fun building my track motorcycle then riding it. Not always, but some days for sure.

That's a really great question actually. And it's a tough one to answer. You can't ride sitting down at the shop welding... But you can't build a bike while you're out there riding. To me, the two go hand in hand. I'm someone who by nature will pick something up, appreciate it, pour over the details, respect the thought that went into it but then my head starts to turn. "How can we make this better?" "...Where can this be improved?" It's a blessing and a curse I suppose! There's a reward to having a level of focus in the shop, deep in thought, directing all of your energy into the task at hand. There is a parallel that's drawn out on the trail too. A singular focus following a line and maneuvering you and the bike over the terrain.

Both definitely enlighten each other. Too much riding, and you're not building. Too much building and you're not riding. I guess when it's that level of passion and focus, a healthy balance needs to be met. That is a challenge. But what is nice about riding is if things are not going well in the shop, I can get lost, found and refreshed out on the trail. That's kind of special in a way. When I'm in the shop creating, I'm fulfilling that urge to build. To make and create. Honestly, I can't tell you which one is better or which one I'd rather be doing. I CAN TELL YOU THOUGH: remove one of those, and there is something missing from my life. I've been on both ends of the spectrum occasionally.

When things are balanced, things are "just so". That's most likely what I'd recommend to anyone, anywhere: Seek balance.

 

[fortyfour]

Post #921 should be a chapter in the Business Bible.

Glad you appreciated it. That's a lifetime to date of experience talking (and I guess I like to say I know just enough to be dangerous). I've been considering putting together an official unofficial "framebuilders' handbook". Maybe that needs to be chapter 1's intro

 

[Alexbn921]

Post #921 should be a chapter in the Business Bible.

Great stuff. I really enjoy reading about the building process. Your welds are gorgeous and it makes me want to trade in my carbon bikes for a hand crafted one. Always lurking.

 

[moto367]

Glad you appreciated it. That's a lifetime to date of experience talking (and I guess I like to say I know just enough to be dangerous). I've been considering putting together an official unofficial "framebuilders' handbook". Maybe that needs to be chapter 1's intro

Sign me up! I'll take an auto-graphed copy please

 

[sbhockey]

Great response. Balance is important. I'm finally getting my track bike out after a couple years off. I'm at a point now where I really miss riding, though I have some project ideas in my head. The hamster has been running double time lately.

 

[fortyfour]

Some recent work aka TIG Weld *** :

















This is what 4 weeks of "work" looks like:



A little of the tooling necessary for purging and heat sync'n :



Holding it all in place to be tacked :



And of course more building...

 

[Nolift911]

Looks great - how many fat bikes do you find yourself building?

 

[bunks-tj]

Please don't take this wrong, as your bike work is amazing (as are you photography skills), but I miss seeing updates on the work space.

Is the shop at a point where you like it, have you reached a point where you feel like you are done. Do you have anymore updates to do?

Again, not a criticism.

 

[Nightshift]

And how! Dialing in the setup and reading up on my welders capabilities / settings. Very different animal than what I've used in the past. Stoked!

Kris, I love your metal shop and the custom work you're doing. I'm in the market for a small 180-225A AC/DC TIG for light use in my home machine shop and immediately thought of your thread here and wondered what you were using to lay down such nice work. So tonight I spent time (a lot) starting back at page 1 and scanning through to see. All I came across was this one pic here of your Miller TIG.

So what model is it that you use and if you were buying a new one today, which model would you buy? Bill

 

[fortyfour]

Looks great - how many fat bikes do you find yourself building?

The next two in the list will be fat bikes. I find myself building a lot of multipurpose "road" bikes. I put road in quote because they are anything but the traditional road bike. Clients have gravitated to the Huntsman build because of it's versatility. Room for 32mm tires (or 40mm for that matter), racks, fenders, good stand over clearance, relaxed handling. Just a purpose built bike. I do see now that there are periods or certain types of bikes as the seasons change. So I'll see "flaps" of certain types of bikes going out through the doors at times.

 

[fortyfour]

Please don't take this wrong, as your bike work is amazing (as are you photography skills), but I miss seeing updates on the work space.

Is the shop at a point where you like it, have you reached a point where you feel like you are done. Do you have anymore updates to do?

Again, not a criticism.

I'm right there with you. I miss the updates too! Here's what's been happening: Time. I'm running a business in it's early stages and that takes a lot of my time and energy. By the weekend, I'm now moving on to projects that relate to my house which was terribly neglected over time by the previous owners. Nothing major-just those projects that when left unattended, turned into mountains instead of molehills. So that is where my energy is focused. Every project on the house is like this: One simple thing opens itself up to "Ahhh ****, I have to replace X, Y and Z before I start A...". We all know this song and dance too well

Long story short, I'm short on time. But not on plans! Rest assured I've got a week in august carved out to make some much needed shop improvements which I'll be sure to share here.

The least I can do I feel is show you what is taking my time up most days. It's just most of the work has been redirected to the house itself where I hang my hat. Here's the front. Poured footers last fall to put on a new deck out the front. That's later this summer, but right now I'm in back working with lots of rot...

 

[Zeke]

I'd like to reiterate that you are an accomplished photographer as well. Beautiful pics. You seem to have the exposure and white balance thing really dialed.

 

[fortyfour]

Kris, I love your metal shop and the custom work you're doing. I'm in the market for a small 180-225A AC/DC TIG for light use in my home machine shop and immediately thought of your thread here and wondered what you were using to lay down such nice work. So tonight I spent time (a lot) starting back at page 1 and scanning through to see. All I came across was this one pic here of your Miller TIG.

So what model is it that you use and if you were buying a new one today, which model would you buy? Bill

HI Bill - thanks for the kind words. So that is the Miller Dynasty 200DX. It's a small but really powerful machine. I'd say it's limit is about .25" thick material. It's ideally suited for small jobs, or detail work. But it can handle pretty much any job. It's duty time that effects it at higher amps. I'm mostly running it hard 1-2 days a week but in the 40-70amp range. What drew me to this particular model was the complete control over the settings in amperage, background, on time percentage, the fact that it's AC/DC, it's small for a small workshop (440sq ft), and the fact that it had a pulse feature which is a great way of reducing heat input on thin walled material (i.e. bicycle tubing). I would not change a thing really if I were to buy new. I'd get the same model. If i had more cash, I'd opt for a liquid cooled torch and setup. It can handle that too and I believe Miller's website show's it as one of the options and set ups. If I were to do anything different, I'd build my own station for it. That's about all I'd change now really. I did replace the stock torch it came with. I went with a CK130, with gas lens, alumina cup (No.8 stub, No 10 and No 12 cups with matching 1/16" tungsten's as well as 3/16" - 2% Lanthanated of course. Blue tips) and their superflex cable. Very light in the hand, not awkward by a long shot and CK Worldwide's support is top notch. I had the CEO call me to answer a question I had. If I were to change that, it would be to get the angled version-although I've modified mine a touch.

Hope that helps. Lincoln also makes something similar in the same category, but I will say I am extremely happy with my Miller and I would not change a thing really. I'd do it all over again the same way.

But if you need the power and duty time of a larger machine, they do make larger more powerful Dynasty's. I think one tip would be to be realistic with yourself of what you really will be doing and what that machine really equates to. I know a lot of people go with a bigger machine "just in case" but that really never is the case. So that would be my tip if I were to give one. Have fun with it though - I love welding that is for sure!

 

[Nightshift]

Thanks for the info Kris. Really appreciate it. I don't normally weld over 1/4" material very often, but when I do, I would always use my 225A stick welder anyway. The TIG would definately be for everything 3/16 and lighter. For sure I want AC/DC so I can also weld aluminum.

A local guy is selling his Miller Syncrowave 180SD but I'm a little nervous about that model based on the people posting on the Miller site about having control board problems. Not sure what I'll do just yet. Thanks again for the info. Cheers, Bill

 

[fortyfour]

Thanks for the info Kris. Really appreciate it. I don't normally weld over 1/4" material very often, but when I do, I would always use my 225A stick welder anyway. The TIG would definately be for everything 3/16 and lighter. For sure I want AC/DC so I can also weld aluminum.

A local guy is selling his Miller Syncrowave 180SD but I'm a little nervous about that model based on the people posting on the Miller site about having control board problems. Not sure what I'll do just yet. Thanks again for the info. Cheers, Bill

Sure any time. For what it is worth, I got mine used with only 10 hours on it for a 1/4 of the retail price. If you are patient, something will come up in good shape used I'm sure. Either way though, the 200DX is worth the investment. Good luck!

 

[Flatland Dave]

Love the build photos. Would really like to see one finished, but not painted. Perhaps just clear coated for protection. Let the colors of the process be the "paint"

 

[fortyfour]

OCD Level Tool RE-Organization

Been meaning to do this one for a LOOONG time. Reorganize my tool wall in the "Bike Dojo". That's basement man-cave btw. Went to the moon and back again :



I have so much scrap left over from the shop build out and general house repairs and such. The screened in porch used to have this giant, useless coat closet of sorts and was made from really big pieces of pine boards. 7'x24" pieces that were about 1" thick. So I cleaned one up, cleared it, and made a shelf from some of the other parts. Then I have all this 1/4" O.D. stainless steel tubing left over in odd lengths when I do internal cable routing. I buy it in 36" lengths, but always seem to have 12-18" stubs left over. So I had a pile of that too-perfect for tool hooks. Stainless square head finishing screws work like a charm to hold them in place and create a nice clean look (I realize now I didn't take a close up... I'll have to do that so you can see what I'm talking about). So stoked to have this finished today and I actually can't wait to build the next bike using this set up. Heck I can't wait to wrench my own bikes!

 

[ric]

Three Stooges, my heros. Front and center.
Really nice work, all around. Bikes, shop, reporting,everything.

 

[fortyfour]

Three Stooges, my heros. Front and center.
Really nice work, all around. Bikes, shop, reporting,everything.

Thanks. Yeah... I love those guys. I acquired that picture a long time ago-can't NOT put it up there to remind me to keep things not so serious.

 

[machine_punk]

Beautiful tool board! I did a much smaller version of that in my first, tiny shop (4' x 8' working area.) That concept is what got me building my reconfigurable tool board, which will have moveable panels with brackets to hold each tool.

I assume you know pretty much exactly which tools you use, otherwise this board gets outdated quickly (you have to make room for new tools).

Exactly the sort of beautiful, detailed work I have come to expect from you.

Oh...I just finished an ideation sketching course at the California College of Art, in San Francisco. I was feeling pretty good about my sketching before the course, but this brought me to a whole new level.

Kev

 

[cderalow]

Funny, working on my own bike I've acquired quite a few of those tools too...

 

[fortyfour]

Here's a before shot so it gives you some perspective :



A detail to show you the pins I made :



And another angle. (For the record, that's my Grandfathers Bethlehem Steel hard hat.) :

 

[Alexbn921]

The tool board came out great. It's such a great feeling to be organized and have everything handy. Nice vise by the way.

 

[YoungMedic]

Schwing!

 

[Modern Jess]

Re: OCD Level Tool RE-Organization

Been meaning to do this one for a LOOONG time. Reorganize my tool wall in the "Bike Dojo". That's basement man-cave btw. Went to the moon and back again :

Nicely done!

 

[utahdog2003]

I spy a can of JP Weigle Frame Saver. Excellent.

Workspace looks wonderful. Nice job.

 

[Pointbock]

If this guy could weld or take a picture, he'd really have future.

I don't know if I should be inspired or defeated by threads like this. My bench looks about 3x worse than the "before" picture. And that's after I cleaned it up.

Seriously, more great work from 44 Bikes.

 

[MarcBergeon]

Awesome stuff as usual man, can't wait for more updates!

 

[smsteve]

Agreed, just another part of the ever expanding picture that is 44 Bikes Frame Shop! Hands down I look forward to these updates on the forum most...and I don't even ride bicycles. I like the feel I get from seeing someone so into what they do, so able to put across what they do to others and so good at capturing it all with a camera. Another two thumbs up from me.

 

[senator52]

Funny, working on my own bike I've acquired quite a few of those tools too...

I was thinking I own ALL those tools and make nothing as nice as 44 does.

Edit: Except the headset bearing press, though I do own a BB30 press.

 

[fortyfour]

44 Bikes POSTERS

You guys asked for it... I'm delivering. These are hand printed by Brainstorm in Dover NH, printed on thick 100lb 18x24 sheet made by the French Paper Co. Signed. Numbered. Archival. Worthy of a frame. Or not. Fit for any fine shop wall or man cave. Limited edition of 50. Get to it.

 

[hoho98925]

Absolutely blown away by this tread!!! Your attention to detail is amazing. Love the thread, love the bikes. Thanks so much for sharing this with us!

 

[HellaFab]

No tandem in my own future. And most likely not in any clients future. My wife and I often joke about tandems: You NEVER, EVER see the guy as the stoker. Just once I want to see a guy in tow with his wife steering the ship. That will be a cold day in hell before I spot one of those I'm sure

My parents have a tandem and I ride the back when we borrow it. My wife can't see past my shoulders and she enjoys looking ahead.

 

[whiteape]

Hi fortyfour,

The internets a wonderful thing when used correctly, I've followed your thread on and off for a long time now, came across it through build threads and was blown away by your attention to detail, your work is impeccable, and your passion for what you do shines through in everything you make,
I take great pleasure in checking back every now and then, to catch up on what you've been doing, as I do quite a bit of fabrication work my self, including tig welding, nothing on your level though, but without the internet, I wouldn't ever have know you or your work existed, you see I'm thousands of miles away, in a little village , in the middle of Yorkshire, a county in the middle of England.
Keep up the good work, your an inspiration to us all.

Regards Kev.

 

[fortyfour]

Keep up the good work, your an inspiration to us all.

Regards Kev.

This is great to hear and I really appreciate the kind words. I've got a lot going on and a bunch more to share! Stay tuned...

 

[fortyfour]

Been a while, but things have been on the busy side. Seems with each passing day, I hear new stories of bikes that were built and delivered and clients getting stoked on their bikes to finding out just how far word has spread in a short amount of time (heck I just got an email from a Triathlete in Egypt...). I finished up a few and have started another batch. These will be shipping all across the United States. Fun to hear about everyone's backyard. Even better to be given the chance to build bikes for them. This one is way out on the "other coast", up there in Portland, OR.













This one went to OK to serve part of it's time as a commuter and the other half as a gravel crusher. (I particularly like how this one came out - really well balanced in both form and function).













After the above shipped, I started (and just finished) a fat bike with matching fork but this one uses the newer 190mm rear axle spacing for 5" wide tires. THAT is a really HUGE rear end. It's amazing. A real game changer for clearances and with Race Face's new Cinch platform cranks and the fact that they have different spindle lengths for both 170mm and 190mm rear ends, I can really fine tune everything. Here's some process shots of all that:

 

[fortyfour]

Continuing on... Once that fat frame above was finished, I have an additional 2 fat bikes / 29+ to build along with a returning client from Switzerland who ordered a matching 15mm x 142mm Thru Axle fat fork to match his frame. (Originally was running a carbon fork when I had not started building forks yet - I did not have the tooling finished when I built his bike). So this all dove tails together nicely: Finish 190mm fat bike, build 4 fat forks for these next 3 builds AND for the returning customer, then start the next 2 bikes which are incredibly similar in size/dimensions so I can double up on all the setups and procedures to increase efficiencies. It will take a little more time overall for the build to be finished, but in the long run, the two bikes next will be built in tandem of one another so saving time overall. Same with the forks. Took me a lot less time and fussing building them all at once - sure that one fork took a week to finish, but I built 4 total. Here's the fork production line going:























And one of the forks finished with it's matching frame. Off to powder next week!





And getting ready for the future 5 mountain bikes and fat bikes... All made in house (these are seat tubes):



And starting one of the next 2 29+/Fat bikes.



Not bad for a weeks worth of work. Getting more efficient and I can see I'm able to build a little faster with those increases in proficiencies / ability. Still riding too. Enjoy.

 

[nicobkn]

I love your thread.

I'n curious as to what your shooting "studio" looks like behind the scenes.Would you mind posting some pics?

Thanks!