Day 2 started with a little bit of measuring to get the frame tube lengths and angles written down. Yesterday didn't involve anything critical, but to put the main triangle together, we needed to know measurements. The top head tube lug I brazed last thing yesterday was looking ok.
First thing to do today was cut the mitres on the down tube/head tube joint. Also a slight modification to the web on the back of the BB. We cut it off and shortened the lug tips so that we could fit a bridge in the chain stays for the mudguards.
Dave had to do a little modification to the seat lug for his jig so while he was on doing that, I had a look at the frames hanging up. Max, one of Dave's dogs has a snug spot right next to one of the work benches.
It was over to the jig to start putting the sub assemblies together. Head tube length is set based on fork design. Chain stays are cut to length and set in the jig to the correct OLN.
Dave has a process to which joints get brazed in which order. While one joint cools down, another is done. The head lugs are so difficult as there is a huge area to get the brass to flow into. The seat lug was even harder. It is a huge chunk of metal that needs lots of heat but not enough heat that you are going to blow a hole in a tube!
With the head tube, seat lug and BB fully brazed, it was time to cut seat stays. A slot cut into the bottom for the drop out with a scallop filed into it. The other end was cut at an angle ready for a flat plate (almost like an oversized seat stay cap on a Raleigh). The two ends of the seat stays should hopefully work out the same length if they've been cut properly.
So the frame is almost ready to come out of the jig. I just have to attach the seat stays to the side of the seat lug and fit the end caps. It can then come out of the jig. The 2 bridges and whatever braze-ons I want can then be fitted.
Another brilliant day chatting with Dave. He and Joe Waugh Owned M.Steels in Gosforth and I worked at Denton Cycles just a couple of miles down the road in Newcastle at the same time, so lots of similar stories and names are coming up
I should start on building forks tomorrow.