Listmembers,
I just wanted to take this opportunity to give some advance notice regarding the "program" I have planned for the Saturday preceeding the 2001 Cirque du Cyclisme.
Prime objective:
For the first time ever I will open my bag of framebuilding tricks in public. I have collected these tricks from other framebuilders like Tom Richey, Dave Tesch, Faliero Masi, Marc Di Nucci, Mario Confente, and Dave Moulton. Each one is a real gem and I use all of them. Contained therein are a euclectic assortment of invaluable tips on how to get world class professional results (with a bit of natural skill and a little practice) on a homebuilt or small scale framebuilding endevor. My methods will show the hobbist how very inexpensive tools and simple methods (and a healthy dose of common sense) can be used to build a quality frame using methods used prior to 1970. Get ready for a "Carrot Top" like show that should fill about 3 hours. I think this format will give the presentation the widest potential appeal to those who might be interested in such a project. I plan to incorperate some "educational" sidebars designed to alert bike affecianatos to some of the subtle things that seperate one frame from another in terms of workmanship, design, materials, and style.
Here is a tentative list of key points
1.How to make and use a full scale drawing to provide key measurements and other details needed in the building process.
2.Tips (no pun intended) on how to add parts to lugs.
3. Basic principals of shaping (profiling) lugs. Also included will be a tip from Marc DiNucci (Strawberry Racing Cycles) on dressing down lugs prior to brazing. Real worksaver.
4.Tips on how to lay out lug cutouts and cut them out. Old school method combined with some of my own, not the jewllery school method.
5.How to slot fork blades and stays for dropouts. This is a method I have developed to suit my needs and style of building. As all my methods are, they work perfectly, are simple, and above all are practical for a small timer to use. I will also demonstrate the method of brazing a dropout to a stay as taught to me by Mario Confente. It's the only brazing operation I actually learned at Masi. The rest of my work was in filing and painting.
6.How to bend fork blades and stays (yes, stays!). This is one of my favorite things to do in front of someone who drops in on me at my shop. People always seem to be amazed at how simple the process is. And still there's some "wrong" ways to do it.
7.How to hand miter tubes. Fool proof method that requires only one special tool which costs about $100 or so. Gotta have one anyway if you're going to build a frame or two.
8.The ins and outs of "tack brazing" and "pinning" frames. I use both.
9. Silver brazing a pair of head lugs. Not investment cast. I'm not exactly sure where I picked up this method. Possibly from Mike Howard, which would make it a derivitive of the Masi method. Will include one of the best tricks I've ever seen for clean brazing insurence. Comes from Dave Tesch and was used at Trek. I don't use it that much but it can really be a lifesaver for a neophyte framebuilder. I use it more during frame repairs, and it can save all kinds of time there. I have to admit, when it comes to "fixit tricks" those guys from the old days at Trek had some really good ones. Another one later.
10.How to clean up lug edges after brazing. Another classic tip from none other than a very young (at the time) Tom Richey. He poped into the Wizard shop one day out of the clear blue and left me with one of my personal favorite secrets. Tom abandoned this one ages ago since he's all about lugless, but I use it constantly. I've never seen anyone else use this one. I just finished detailing every single lug and fitting on my Hetchins Millinium frame using this method. I hope to debut the Hetchins at the show, although it is not my highest priority.
11.Lug filing basics and demo. Whip out the 12" Bastard (file) and get busy! To really do this right I need some rippin' rock music to put me in the "mood" and establish a meter (no, really) to the strokes. Nothing like a little Frank Zappa blasting (actually not too loud, I have to concentrate) or some early Cream. Surf music works well also.
As special features I will also exhibit;
The Faliero Masi origin seat stay centering tool. Simple and effective.
The Dave Moulton origin "British Bender" (as Tesch was so fond of calling it). Handy tool for the small time builder, and Oh so English!
A simple way of holding lugs while you work on them. Picked this up from Ron Smith, the original Masi painter, and the source of much of my filing knowledge.
A few simple tips on building forks so you won't look like an amature.
The other classic Trek "fixit' trick. Only used in frame repairs but absolutely invaluable when working alone as I do. This method effectivly gives a solo framebuilder another set of hands. Since the big guy upstairs failed to notice that if two hands are good then four hands would be BETTER, this is the next best thing. Allows a solo repairman to do delicate repair operations without tearing lugs and whatnot apart. Totally cool trick!
Last but not least, I will demonstrate the Mario Confente "internal chainstay stop". As simple as this is, it's still one of the coolest little features for a custom frame. I've been doing this for years and never tire of it. Only works on some chainstays; deffinitely not Hetchins!
If there is any time at the end (yeah, right!) I'll answer questions; but nothing about religion or politics please. I want this to be a friendly discussion. Also, I'm not a techno geek, so don't expect me te be spewing technical data and so forth. Just knuckles and elbows framebuilding, John Wayne style. Don't forget to bring a light pair of sunglasses if you want to watch the brazing demo close up.
Final detail. I have already mentioned this to Dale, and perhaps someone will able to help Dale arrange this since he already has a lot to do. I feel that there's a pretty good chance I won't be spilling my guts about framebuilding to a public audience possibly ever again. Therefore I thought it might be a good idea to video tape the whole fiasco for a few reasons. One is that those who don't attend the Cirque will be able to see the event anyway. Two, possible sale of said tape could help offset some of Dales' costs for the event. Any help?
Brian Baylis
Insane Diego