My new single speed build

[shaper]

At the rate of the kudos and interest you may end up starting a new forum classification of frame building as there seems quite an interest in what you are doing and how you overcome problems.

 

Please also highlight the headches, mistakes as well as the successes as all is of interest with regard to a build from scratch, especially with carbon.

 

Keep us posted

[jcmeyerSS]

Ledge-gend-dairy!!!!!!

[sometime]

Respect!

[rock]

very ambitious.....cant wait to see more pics

[BogusOne]

So having a day job sux big time as i do not get to build permanently. Really only get to build for like a couple of hours at night....

 

Headaches someone mentioned earlier, well as im sure most of you have guessed that for some of the shapes i use normal polystyrene to shape and then wrap that with carbon.... The carbon wrapping is easy, getting the desired shape on the foam is a whole different story

 

A lot of test pieces are made before i actually settle on the final shape so i guess one can say that there is a lot of trial and error involved.

 

Here for example is a rough piece i made last night for the seat stays... Got this one right after the fourth try

I still have to sand it smooth etc so dont expect too much of it as in the picture... Hopefully by Sunday i will have more to show you.

 

As for the questions about gusseting the frame... Well keep following to see what i do with it

 

This is my 1st prototype but i can assure you it wont be my last. Im having a blast doing this and will for sure continue and hopefully evolve with each one i build....

[V12man]

BogusOne - shaping polystyrene is very tricky - try useing Polyurethane foam the same as used for surfboard blanks - this is a lot easier to work with.- cuts and sands very easily and well using normal woodworking tools - polystyrene is a nightmare to get a good finish on compared to this.

 

http://www.surfblanks.co.za/

http://www.safarisurf.com/

http://www.rsablanks.com/

 

are local suppliers I am aware of - there may be more, and some may be out of business - been a long long time since I last looked for blanks.

[@ndy]

This is a cool project. Maybe I can help with this one or any other budding frame builders.

 

I work for a company building large products out of composite materials and we throw away enough carbon and polyurethane foam excluding resin to make several bikes a week. It is criminal how much we waste and I would rather see it go to a worthy cause like this one. We even pay to have it thrown away!! PM me if you are interested in and taking away some of our valuable rubbish.

[BogusOne]

BogusOne - shaping polystyrene is very tricky - try useing Polyurethane foam the same as used for surfboard blanks - this is a lot easier to work with.- cuts and sands very easily and well using normal woodworking tools - polystyrene is a nightmare to get a good finish on compared to this.

 

http://www.surfblanks.co.za/

http://www.safarisurf.com/

http://www.rsablanks.com/

 

are local suppliers I am aware of - there may be more, and some may be out of business - been a long long time since I last looked for blanks.

 

Thanks for the info on the polyurethane foam there V12. I have worked with polyurethane foam before and yes it does shape much easier than the polystyrene but it has a drawback... If i use the polyfoam it will have to stay behind and ads quite a considerable abount of weight (yes in a way all cyclist are weightweenies )

The polystyrene is quite easy ro remove from the tubing once the tubes and shapes are formed...

 

 

Just got some more supplies

UD carbon to strengthen certain areas and epoxy to "glue" the mitred joints before they get wrapped.... Happy days

[Overlord]

Oi BogusOne!!!!!!!!!!!!! You are supossed to work. Big Brother is watching you.

[BogusOne]

Oi BogusOne!!!!!!!!!!!!! You are supossed to work. Big Brother is watching you.

 

headoffice is closing early today

[Overlord]

headoffice is closing early today

 

But I am still open

[V12man]

"The polystyrene is quite easy ro remove from the tubing once the tubes and shapes are formed..."

 

I guess you are dissolving it with acetone or some such - Polyurethane foam can also be dissolved = think it was Xylene or Methylene Cloride that dissolves it, but a bit of r&d on that will confirm what solvent to use - I am sure the blank manufacturer will be able to tell you.

[Wazza_pe]

I wish you all the best with this challenging, but exciting project.

I look forward to tracking your progress.

[xtcman]

Those interested in doing this or similar frame builds try this site

 

www.instructables.com

 

And just type in the type of frame your looking to build,steel or carbon.

[xtcman]

Sorry guys, its www.instructables.com

[ThePubSA]

Good Job BogusOne