I've been working away at finishing some final work before I can start on customer projects for the show. Most of it has been fairly mundane work, hardly worthy of presenting and capturing your attention with, but I did snap a sequence of shots for one special project.
Today, I thought I'd share with you the Shimano Direct Mount Front Derailleur and what it takes to fabricate the necessary mount for the frame to utilize it.
To machine a mount, Shimano provides a tech document with most of the desired dimensions, though I found that I needed to modify a few for better performance and aesthetics.
To get started, I cut down a piece of stock 1/2" x 4" steel into two pieces that will eventually become four mounts. I then face milled all the pieces to insure clean, square dimensions to begin working from. Once machined to my desired starting dimensions, I grabbed the edge finder to establish a known reference point.
Multiple passes and a little patience helped me achieve the final depth necessary...nice and clean with a .01" tolerance.
Holding it in place on the derailleur, you can see how the two pieces fit and the vertical adjustment that is possible.
Should make for a clean, custom touch on geary bikes. A bit more time on this end to do it right, but well worth it for the benefits.