Fixing a Victorian

I think I have the fork forming sussed!...well it works in my head! ....I think 😂 The brazing....I really don't know enough about but we're talking of a time when skill was common place... everyone had a trade!
I can't see the forks being formed to a curve after being made into a tube....I reckon that would cause way too much stress to those toothed joints...the braze wouldn't let go but the steel would.

Does the joint size between main tubes,forks and stays vary much or is it all consistent and the same?

I'll have to have a look at the Mary's falls locks....big stuff..like it! I have french cousins who do big maritime civil engineering.
It’s in Sault Ste. Marie Michigan, 230 km east of me. It’s where Lake Superior dumps over a rapids, then through the St. Mary’s River and into Lake Huron. Uncle Georges lock is currently not used as it’s too small. Their going to take his and another small lock out and replace it with one 110 feet wide and 1200 feet long to accommodate the new Great Lakes freighters, which are 105 feet wide and 1000 feet or a little more long. The old locks were narrow, but took two shallower draft 600 foot freighters at once. These 600 foot ships are almost all gone, replaced by 729 foot freighters that can get into the St Lawrence River and the 1000 footers that stay in the upper Great Lakes. The Edmund Fitzgerald was 729 feet long. We do freighter watching but it’s lost it’s appeal as the big ships each replace many more interesting smaller ones. Here is the Locks at the Sault with a footer in the big lock. The two locks on the left are planned for replacement. This is an old photo, perhaps the 70s as these smaller ships are just about gone. The ones that remain have been fitted with a huge self unloading conveyer on the deck. E635D84A-020F-4045-AE1D-1876845C2A85.jpeg
 
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You took the words out of my mouth. This is what I think:
a) Forget mega industrialisation at the bike builder. While it's clear there were big bucks in this bike and potentially big bucks to
gain, this is not Ford we are talking about.
b) Don't rule out man power. And a fleet of people if necessary.
c) I too think the sheet metal is made - somewhere - to a specification. It is formed, stamped and delivered, except the forks!
d) There is no post bending at all of the fork, it's formed, and brazed and finished ni house at the bike builder.
e) Who ever did the tubes wasn't a bike designer. It's so blown out and on another level. What I do think, the bike designer did
what they are good at, design the fork, rake, crown, and specified the tubes etc.
f )To do the sheet metal, like you have said, requires machinery for repeatability.
g) If you took a wheel punching regular slots for a dovetail, it would not account for the curve. There needs to be a linear press
to account for minute variations of dovetail dimensions at the curve.
h) A linear press - the tooling - could only be made based on a positive prototype. The machine being the negative.
i) The only way to make a positive prototype I think is by making a template using all the old tricks in the book.
j) I don't think we should rule out a bit of sub-contracted forming and a bit of manual forming in house at the bike builder,
what I'm saying is there could be an initial sheet punched, and it's filled down where necessary manually to allow for the curve.
k) ......back then....people got there hands dirty. Engineers and technicians were king. The bean counter didn't meddle with the product,
nor have any particular say in the matter. The bean counter had to fix things behind closed doors.
I saw on the net on a site about old Chicago that the monarch bicycle factory had 5000 employees.
 
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I think I have the fork forming sussed!...well it works in my head! ....I think 😂 The brazing....I really don't know enough about but we're talking of a time when skill was common place... everyone had a trade!
I can't see the forks being formed to a curve after being made into a tube....I reckon that would cause way too much stress to those toothed joints...the braze wouldn't let go but the steel would.

Does the joint size between main tubes,forks and stays vary much or is it all consistent and the same?

I'll have to have a look at the Mary's falls locks....big stuff..like it! I have french cousins who do big maritime civil engineering.
It’s consistent, must be machine cut, but the pattern on the fork and stays are different.

zipper pattern on the forks

3027CCFB-0AAB-49A0-9218-E7B30B89BF5F.jpeg
Square pattern on the stays 29844853-048C-4339-96DF-B4CFD601B95C.jpeg
 
Holy moly....
Think I've found something!
Random Google image searching just about every way I could think of calling that tubing and I think I've stumbled on it!!!
 

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