What the hell is he building in there

Southwest Montana SCCA discussions for the 2008 season.
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DaveMk1
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What the hell is he building in there

Postby DaveMk1 » Tue Dec 30, 2008 3:31 pm

So I had a fun work project that I thought I'd share. I've built a number of tandems over the years but this is the first one with my name on it so it was that much more fun. Building a tandem frame is a huge amount of work (about 3 times the work or a normal single bike) so it took me a solid two weeks at the bench. The photos show it all finished right before sending it off to the paint shop where it's being sprayed a metallic sunset orange.

If you look closely you'll see some shinier lumps in the middle of the frame. These are "Couplers" and they unscrew to allow the bike to be broken down and packed easily for travel. Believe it or not the bike will break down and go into a 26"x26"x14" case for airline travel and it's not "oversize" so there is no extra charge to carry it. I'm thinking I could graft some couplers into my Birkin chassis (it's tubes after all) and then be able to stick it in the back of the Mini to get to events.

This was build for a production engineer at Toyota - he's the guy who makes the call as to what factory gets shut down and what one gets to work. I guess he's got good job security.

Hey - thanks for looking.

Dave

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Re: What the hell is he building in there

Postby Mel Kuipers » Tue Dec 30, 2008 3:58 pm

would like to see the pics but my machine just shows a box saying there is a picture somewhere...had the same problem with Russ' pic, but then it showed up...do you know anything about this machine resistance I am getting?
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Re: What the hell is he building in there

Postby DaveMk1 » Tue Dec 30, 2008 4:14 pm

rosebud_59047 wrote:would like to see the pics but my machine just shows a box saying there is a picture somewhere...had the same problem with Russ' pic, but then it showed up...do you know anything about this machine resistance I am getting?
Mel


No I don't know what's up with that. I see pictures.

Is it possible that you've been drinking heavily and you are blacking out?

Happy New Year Melo Mel.


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Re: What the hell is he building in there

Postby rkaiser » Tue Dec 30, 2008 4:36 pm

I think it may be because the url's for the images are on another forum that requires log-in.

I don't see anything either
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Re: What the hell is he building in there

Postby JoeE » Tue Dec 30, 2008 5:01 pm

rkaiser wrote:I think it may be because the url's for the images are on another forum that requires log-in.

I don't see anything either


Ditto, when I open the image in a new tab I get a login screen for Velocipede. :)
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Re: What the hell is he building in there

Postby DaveMk1 » Tue Dec 30, 2008 5:04 pm

I think Russ gets the prize - I'll try it this way.

Dave
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Re: What the hell is he building in there

Postby JoeE » Tue Dec 30, 2008 9:26 pm

Wow Dave, that is seriously cool. Did you make the coupler things?
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Re: What the hell is he building in there

Postby DaveMk1 » Wed Dec 31, 2008 7:30 am

JoeE wrote:Wow Dave, that is seriously cool. Did you make the coupler things?



Nope I buy them. They are an impressive piece of stainless machining and silly expensive. Lots of chips left on the floor I think.

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Re: What the hell is he building in there

Postby Mel Kuipers » Wed Dec 31, 2008 7:40 am

now I see them...boy those welds look great in close up...would like to see the finished product when you get there...happy new year...Melo
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Re: What the hell is he building in there

Postby rkaiser » Wed Dec 31, 2008 7:47 am

Thats pretty cool Dave! Are the shifter and brake cables pretty encaused in housing all the way back to the brakes/derailers?
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Re: What the hell is he building in there

Postby DaveMk1 » Wed Dec 31, 2008 2:20 pm

rkaiser wrote:Thats pretty cool Dave! Are the shifter and brake cables pretty encaused in housing all the way back to the brakes/derailers?


Nope. The cables are all out in the open as normal but they have "splitters" in them so the cables can be parted (unscrewed) to allow the whole thing to be broken down easily. This frame is set up for disc brakes as you can see by the tabs on the fork blade and near the rear dropout.

FWIW the joining method on this bike is known as "fillet brazing" and it is different from welding. The joints on this are done with very careful heat control with a torch (oxy/acetylene) and melting brass onto the steel tubes to make the joint. After the joint is brazed it is polished to give it the look you see here. By fillet brazing, instead of welding, I can use thinner and lighter tubes as fillets take much, much less heat than does welding and it's the heat used to make the joint that can weaken the whole deal. When laying fillets I only get the tubes up to about 1800*F while welding (which actually melts the tubes together) requires over 3500*F. This can save a good bit of weight and give a nicer ride because the tubes don't need to be really thick to be strong enough after they weaken form all the heat.

It's fun stuff if you are like me and have no life or friends.

Dave
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Re: What the hell is he building in there

Postby Mel Kuipers » Wed Dec 31, 2008 2:59 pm

Dave...I have met Karin, so I know you have a life...and I will be your friend for "take a friend to work day"...given that I spend my work time with concepts and ideas, I am always very interested in folks who go to work and acturally make things...am especially taken with the brazed joints--they are beautiful...so some day next summer, I would like to come see you work...I won't get in the way or break things...and afterward will gladly take a test, as long as it is multiple guess...happy trails, Melo
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Re: What the hell is he building in there

Postby DaveMk1 » Wed Dec 31, 2008 3:29 pm

rosebud_59047 wrote:Dave...I have met Karin, so I know you have a life...and I will be your friend for "take a friend to work day"...given that I spend my work time with concepts and ideas, I am always very interested in folks who go to work and acturally make things...am especially taken with the brazed joints--they are beautiful...so some day next summer, I would like to come see you work...I won't get in the way or break things...and afterward will gladly take a test, as long as it is multiple guess...happy trails, Melo


That my friend is a deal. I'd love to have you come by. I've done many many hours of torch work with someone watching closely and most folks have gotten out without major scars.

Anytime.... let me know.

dave
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Re: What the hell is he building in there

Postby Alex » Fri Jan 02, 2009 3:48 pm

Man, forget painting it, those brazings are a work of ART! Absolutly beautiful.


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