44 Bikes Frame Shop

[Sanko]

Hello. I put this thread in my bookmarks, thanks a lot man!

[kpc655]

great building. i love the older buildings. they have so much more character even if it is a PITA to make anything square!

[e30bradley]

great job with this shop build.. I just read it from page 1-12 and I'm pretty impressed. I'm also an avid cyclist and my frame is actually getting a bit small. I'm going to PM you.

[fortyfour]

Square? That's a mouthful. Nothing is square in this space. The floor has been the biggest challenge to work around. It was a total PITA x10 to build that stud wall on the floor and then get it in place. I was using blocks and shims like they were going out of style. Don't think I posted up this process shot of putting part of the stud wall together:



When I had this finished, I had to crank the Bridgeports table all the way to the left, move the wall past it, pivot and then move the Bridgeports table all the way to the right while holding the wall up with one hand. Fun times.

[Bib Overalls]

In the real world "level," "plumb, and "even" are theoretical concepts.

[HIRISC]

Very, very impressive all the way around. The setting, the transformation, the craftsmanship (great welding) and the photography.

Kudos.

[supra90turbo]

Originally Posted by Bib Overalls

In the real world "level," "plumb, and "even" are theoretical concepts.

Agreed.

On another note, 44... I am without words. I wish I had your clarity when looking at objects and spaces.

[bmwtinut]

Originally Posted by studlyrs

Great work on the shop and bikes. I checked out your website and blog. I always wondered how many guys on this journal frequent mtbr.com.

I was thinking the same thing. Reading this just gets me stoked to go out and ride! Instead I am inside designing custom medical equipment on Solidworks.

[LoRollinLS]

This place keeps getting better and better.

[d0nk3y]

Window in rafters = Skylight.

[fortyfour]

Again: Thanks to all for the kind words. Things are coming together nicely. A little slower than I would ideally like, but good things take time as they say.

@supra90turbo: Those are powerful words and well said. I've found the more difficult tasks I have taken on over time, that clarity of vision gets just a bit easier each time. But then again, the most simple decisions can take the longest to get "just so".

@bmwtinut: I hear you on that. Glad to provide some stoke though. That's what this whole thread is about. I had to "make" some time today for a much needed ride:



Watch it here.

[johnny ro]

Good stuff. Thanks for the great read.

I also have shop in NH (03832) but its not like yours. Mine was already clean and square, now modestly equipped for weekend hobby vehicles.

I have four tentative recommendations.

1- Try Craig Deoxit on the Bridgeport switchery. It works well on Stratocasters and McIntosh equipment.

2- Beware concrete floors in NH. In unheated spaces, they stay cold, and cause heavy condensation. Steel rusts fast. Bye-Bye former museum piece Miata. Hello, Amsoil heavy rust protector spray. Midwinter thaws will see dense fog pour inside the shop if you so much as open a door.

My next shop in NH will be a real NH barn, an old barn with basement and main floor with loft. Activities on main floor.

3- Be aware of high quality disposable rubber gloves. $10 for 40 at Home Hell Depot. They are great for shop time. Keeps hands from aging visibly within six months, and clear of petroleum products.

4- Shop stereo FM appears to be missing. I am not advocating that you move beyond simple stereo college station music to internet connectivity for each item in the shop.

Kindest regards, John

[FFAC40]

I just stumbled across this forum, found this thread, and 2.5 hours later...I am seriously impressed with your creativity, determination, and flat out talent. I don't know anything about milling, lathing (if that is how you spell it), or the like, but I can see your passion and the fact that your are pursuing your dream is, just like everyone has said, inspiring. I will be sub'd for this evolving build!

[wlspdshop]

Just amazing....love it and nice work.

[fortyfour]

@johnny ro: Thanks for the thoughts and recommendations. Much appreciated!

You are right on the cold floors in NH comment. This is one of the reasons why I opted to build, insulate and heat the space before the floor is repoured. If I invest that much in a new floor, I want to have the space prepared to protect it.

Which brings me to one of the most important factors in any space: Sound. I'm working on this. I have 4 speakers poised to go to 11. I have a call out to friends and family for a receiver. I was kicking the idea around about running internet from the house out there when we pulled the wire from house for power, but opted not to. I want to be 'unplugged' when I'm in the shop. No telephone. No internet. I want to work, look outside and listen. That's it

Here's some history for everyone: My grandfathers welders manual. You can see his penmanship / business name (Superior Welding Co.) in the top left in pencil:

[wxm]

Originally Posted by fortyfour

The black bike can be run as an ss by flipping / switching the dropouts (pics are from an earlier prototype):


44 f1 Drops - Geared mode by BLACK CAP Studio, on Flickr


44 f1 Drops - Single speed mode by BLACK CAP Studio, on Flickr

The red bike uses a bushnell EBB:


44 Snake Driver - EBB by BLACK CAP Studio, on Flickr


44 Snakedriver - Paint #3 by BLACK CAP Studio, on Flickr

The sky is the limit with a custom build - if the customer wants sliders or an EBB I can build to their requests. I just personally don't like sliders. I do however like how the Bushnell version of an EBB works with the expansion bolt vs the set screw types.

Just a thought. It might be more cost/weight effective to keep a regular bottom bracket, but make a horizontal sliding rear drop-out (Kona did that in the Sutra).

Hey, Love your built (Bike and Shop)!!!!

[CarterKraft]

Originally Posted by fortyfour

@Muibubbles (nice handle btw!) To bend the tubes, I'm using a JD2 Model No. 32 bender. More info here. It is modified though-the followers on these work fine for thicker walled tubing but the majority of the tubes I am welding/bending are .035" wall thickness and thinner. The key to bending thin walled tubes is to have the tube at the point of tangency fully supported. The achilles heel of these benders is that at this point, the follower does not have support. So I machined a few round followers and that really fixed the bender and allows it to bend really well. The other part that I modified is how the tube is held. Stock, you need to basically waste 3" of tube and there is no reference point that is consistently fixed. So I made a clamp that holds the tube differently and closer to where the tube begins to bend.

Love your shop build, it has the feel of a "million dollar" production hidden in the woods.

I would love to see your bender mods. I have that bender and while I haven't bent any small tube like you are doing I might be able to benefit from your modifications.

[Honest Bob]

Awesome work!

[Spam16v]

Originally Posted by wxm

Just a thought. It might be more cost/weight effective to keep a regular bottom bracket, but make a horizontal sliding rear drop-out (Kona did that in the Sutra).

Hey, Love your built (Bike and Shop)!!!!

Sliding drops are a weak link in the direct line of fire for extreme stress. EBB's aren't a perfect solution, but are a very viable option vs. a sliding drop and added links in the chain of weaknesses.

[paredown]

A friend from RoadBikeReview (GirchyGirchy) posted a link to this thread--in response to a thread I had started about my "dream garage."

I have read and enjoyed every word of this thread--dad was a machinist and tool and die maker, so seeing the old tool case, the Starrett and Hobart brochures (not to mention the Bridgeport)--and the nice shots of good clean welds, was both a trip down memory lane and an inspiration. Everybody needs a welder and a milling machine in their garage!

You've now got me thinking I need to hunt up and recycle a post and beam structure--nothing on the property now except the house--since it will give a similar feel to your space, and keep stuff out of the landfill. Or go to timber framing school and build from scratch.

I'm finishing off the last section of a major house reno, and the tools have to go somewhere!