Bike #2 Design is...Complete?

Let’s say ‘mostly’ complete. I think I’ve settled on bends in the rear triangle. Not completely sure because I need to make some test bends and see if it sucks in real life or not. Otherwise, the spec/build kit is generally decided. Been practicing brazing on my own, and you know what? It’s a helluva lot harder without a master frame building watching over your shoulder. Whoda thunk it…

Even with the crappy job I’ve done on my first few test joints, the “beat it with a hammer until it breaks to see if the tube fails first what with all that hammering test” PASSED WITH FLYING COLORS! And some chunks of flying flux. Gotta protect those peepers w/ plastic peeper shields. You know…what do people call them….? Oh yeah, safety glasses! That’s it, I was way off.

Bike frame design...makes me a different kind of hangry.

TLDR: Boohoo, poor me, I’m being a big fat crybaby. But I have a real question at the end.

Hangry in this context is not hungry/angry, but happy/angry. Happy because it’s fun, and I get to learn a BUNCH of stuff, specifically/right now, the interdependence of all the features/dimensions of a bike frame.

Angry because of the INTERDEPENDENCE of all the features/dimensions!

AHHHH! I change one thing, and it screws up a ton of other stuff! Or, I know a lot (not all) of the little things to check, such as heel clearance, but when I actually get to the point of checking it, now I have to change my very simple chainstay into a complex, swoopy thingy, so that, oh, I don’t know….I can actually ride the bike?! Seems reasonable…to, um…be able to do that. So a-changin we shall go.

Then, mix together the sudden harsh reality of “I don’t know how to curve a bike tube” and “the tools required to do a GOOD job at that cost a LOT of money”.

BUT, *deep/calming breath*, I know it will be fine. Eventually. Provided I keep working towards this incrementally, in a business-like fashion, I know, with certainty, I will get there.

How much heel clearance is enough though? I guess I should check some other bikes…


My very first bike build, which I also painted myself! Came out pretty awesome. I’ve only a few rides so far, but the bike feels great.

Check out Yamaguchi’s Frame School in Rifle, CO. Yes, it’s expensive. Yes, it’s worth it. Yes, YOU will do almost all the work, but he will help where it really matters, such as fixturing, techniques, the tricky parts of brazing delicate features, etc. He’s very patient, great guy, good teacher. And at the end, you’ll get a custom sized/spec’d bike and fork. I also added the stem class because if you’re already there, you really should. The stem was actually the first part we completed, so it was nice to hold a real part while waiting for the frame/fork to progress.

I used paint, and they liked it enough to feature my bike on their Instagram. The paint definitely has a learning curve to it, but was very much worth the effort, and it works really well.

I have grand plans of a full write-up on the experience, but I’ve also better things to do. If anyone has questions, please reach out and I’ll do my best to answer them.

Bike Ramp2

I originally saw this on Seth’s Bike Hacks youtube channel and duplicated it as closely as I could. I wanted to formalize what I did in case it sucked, or was awesome, I could readily duplicate it. I deliberately made this more on the mellow side as kickers go, as I’m not so great on the bike if that bike is flying thru the air.
I used 1/2” plywood for decking, but even with what appears to be a ‘gentle’ curve, I could not get the ply to conform to the curve without partially sawing thru the underside w/ circular saw….made lots of partial cuts thru underside, then screwed down at the two lower corners, then jumped on the ply to ‘crack’ it into the curve shape. Even after that, it had enough residual tension (trying to straighten itself back out) that a few screw heads broke off when trying to fully screw it down to the 2x4 cross-supports. Wear safety glasses.

And wear a helmet, don’t hurt yourself, don’t whine to me if you don’t like this design, but if you have ideas for improvements, I’m partially made of ears.

Bike Ramp 2 PDF

Manual Machine

Completed this project a few weeks ago, just haven't updated my site, so here are pics of the completed Manual Machine:

PDF plans download below. Wear a helmet. It’s not my fault if you hurt yourself. Don’t whine to me if you don’t like this design. But if you have ideas on how to improve it, I’m partially made of ears.
Manual Machine PDF

I don't like the word "can't".

Ahh dropper posts.  To me, the single best recent innovation in cycling...although it relies on ideas from the first days of office chairs.  When I added a Pivot LES to the fleet, it didn't have provisions for internal routing for dropper post, and I was told "I can't do that on that bike".  Well...ahem, I beg to differ.  The existing cable entry cover already required two holes thru the carbon frame, all I had to do was enlarge a hole, design my own piece, make it work.  Now I would never encourage anyone to take a drill and file to a brand. new. carbon. frame...but I figured someone smart over designed this frame to have two closely spaced holes, so someone hold my beer...drill drill, file file, route cable, cuss at least once, route cable some more, and POOF, dropper post compatible.

Base for Park Tools Truing Stand

It has little pockets for spoke wrenches, etc. when you're getting your wheel build on.  This was the first time I used my rapid prototype machine to squirt out parts from rubber-like filament, so I could get me some squishy feets on the bottom.  Mm-mmm, worked out just fine.

Bike Rack

My bikes like to sleep inside the house if possible.  Buuut, my wife didn't like the room looking like a bunch of raccoons parked the bikes.  POW! BIKES UP ON THE WALL INSTEAD OF BEING ALL UP IN YO FEETS.  It's pretty magical.

Single Speed Wooden Bike Drivetrain, with Spring-Action Tensioner!

I watched a neat video from a favorite site of mine, where a guy made some wooden bike cogs/chain.  I thought I would give it a try, to see if I could figure it out too.  Created my own CAD design templates for gears and chain cogs a while back (used it on the Tum-Bling Machine), so it came in handy for this too.

Burley Trailer, Meet Karate Monkey

I didn't like the way the original trailer mount liked to unscrew the left hand acorn nut whilst hauling the kid around, uh, so I fixed it.