Process The Naked Process

The Customers desires are reviewed and negotiated with the help of BikeCAD

The design is finalized, drawings sent for approval. Everyone is excited!

Mission control. Parts are ordered. Reality is checked.

Everything is ready to build.

Bits waiting to be all forked up.

The faithful jig; "Emmy".

Tubes are are mitered and checked for fit. If they are too short then they are re-cut to make them longer....

Seat tubes getting there binders brazed on. Notice the patented torch holding technique.

Some tubes are mitered on the lathe. Others are done on the mill.

Chainstays being fit into the jig.

Some final shaping is done with a file. check, file, check, file, repeat.

Nice tight fit. Easier to weld and less distortion.

Frame is tacked in the jig. In this case it is tig welded. Similar process for brazing. Lugs are done completely in the jig.

Final welding is done out of the jig. Alignment is checked and re-checked through the welding process.

A fresh naked tig weld.

My own bender for handlebars.

Putting a custom s-bend in some seatstays

Holes for waterbottles are drilled before the frame is put together to assure perfect alignment.

Some custom cut couplers. This was done to match a nice lugset.

Cast dropouts always need to be cleaned out to insure a proper fit.

An Army of head badges freshly formed and polished one by one.

My first bikes had this detail on the seat-tube so I hand cut them for each one. What was I thinking!

Mitering tubes on the milling machine.

Building bridges.

Every frame is stamped with a unique number and/or name.

The bat cave.

All frames are media blasted in preparation for painting

Some final sanding and polishing is always needed.

Surface is thoroughly cleaned and prepped for paint.

More to come:

Alignment

painting

components

riding!