The Griswalds head to the handmade bicycle show...

that's what the locals guys at the shop said it looked like once I had the trusty old Volvo wagon loaded up with show goodies heading for UPS yesterday :)

For those that may be unfamiliar, the Griswalds were a family in National Lampoons Vacation that traveled the bredth of the US in a heavily loaded station wagon. Unfortunately, Christi Brinkley did not flag me down like she did Chevy Chase in the film. Regarless, despite the critisism my poor old car takes, she still delivered the goods like a champ.

I had to chuckle once I got to UPS...the customer area of the local distribution center is so small, once I got all the bike boxes inside you could no longer open the door. It got pretty cold for the folks who got there after me and had to wait in the 12 degree weather until the clerk had processed enough of the boxes to start moving them. I did not make too many new friends that day ;^)

The actual loading was preceeded by a flurry of activity; bike building, disassembling, and packing.

When time is of the utmost importance is when small things always seem to go wrong. Who was it that said "adventure begins when circumstances no longer follow the plan"? I did not have much "adventure", but it is a bit frustrating when you think you've got it all figured out just to have reality smack you in the face.

Example...

finishing up Roy's build I realized that I had overlooked a small part spec...the US distributer of Rohloff hubs does not include an OEM axel plate with the hubs. Instead, they give you this awful looking torsion armiture that extends under the length of the chain stay and attaches in place with a hose clamp...ick! Usually, I have to order one directly from those gifted German engineers myself, somehow in the midst of activity of late, I forgot this small detail. Now that the shipping deadline for the show was critical, I had to act FAST! So, two hours on the mill, one minute on the TIG welder, and a quick trip to the paint booth and we were back in business. Silly me, I'll never forget that again (fingers crossed :) )

I did a quick build of the polka dot bike, less the Rohloff cables attached, and thought I would share a few pics as this will be the conclusion of this neat process.

Your standard side shot...ummm, where are the cranks you say? Bill has been busting his bum to get the new Hot Rods just where he wants them. I'll likely see them at the airport, just in time to put them on the bikes for the show. These first sets will truly be show pieces, as the heat treaters could not get us the tempered spindles back in time. If all goes well, the functional products will be waiting for us when we get back, then we'll be able to ship these out to all those who have been waiting sooooo patiently.

I really like how the stem/bar binder came out. So much cleaner than having those ugly pinch bolts protruding out the back of the stem.

Some headbadge lovin...

And a little "made by" credit...

I got a special delivery tonight. Know what it could be? Here's a little hint, a lot of people have been asking for the one off my back.

More info tomorrow morning.

cheers,

rody

Filling the world with color...

It's been a long haul the last 5 days. I've been working on paint for the show bikes and the experience over the last couple of days has once again reinforced what I already knew...


It always takes longer than people think it should (including me :) ) and you can not rush paint...you'll spend more time in the long run.


I had 5 frames, 4 forks and a butt load (that's a whole bunch) of bars to spray to get ready for NAHBS.

Long story short, I've slept 12 hours since last Thursday, look and feel like crap, but ended up with some really awesome finished products.


Without letting the cat out of the bag and showing you the show bikes, I thought since we've chronicalled Roy's bike build, I'd share the photos of his paint coming together, so here we go...


I first start off by inspecting the frame to insure that all the finish work is complete; welds closed, no pits in the brazing, all vent holes taped over, paint bolts in the bosses, etc...

Next up is a trip through the blast cabinet to clean the frame and give the material a consistant finish and a little tooth for the primer to seat into.




Once out of the cabinet, the latex gloves go on and the paint begins. I use PPG products the majority of the time, throwing in some House of Kolor for the super fancy stuff. The primer I use is some super tough stuff, like an Armadillo hide, it takes a lot of work to get through it. A solid primer is very important to the protection of your frame, as liquid paint will chip, but it should only reach the tough primer layer, protecting it from the evil oxidation process of rust.



The primer layer is dryed and then sanded to give a super smooth base for the color layers to come. I use 600 grit paper, dry sanding in even covering strokes.



The finished sanded frame is then carefully blown with filtered compressed air to make sure that all dust and fine particulate are removed.


Next up is the series of base colors, masks, and then clears.


One of the things that I really enjoy about painting is developing the paint scheme and visualizing how it is achieved, kind of like backwords thinking.


Roy gave me some guidance on the colors he desired but left the design up to me...this always makes me a bit nervous as I really hope that what I come up with is met with enthusiasm from the end customer. In this case, I struggled with a design incorporating the colors Roy wanted; olive green, off white, yellow/orange highlights. I had two false starts where I backed off and rethought. I finally came up with something that balanced the conservative (by my standards :) ) colors and my need for fun. Roy got a cream panel and polka dot with grunge green background. I was hesitant about the colors, but they really came together nice.



I began by laying down the cream white. Once in place, I dryed it and then began the masking. A panel on the down tube and seat tube and 4 different sizes of dots across the canvas.


Once the masking is complete, I sprayed the green on top, which will end up becoming the base background.


Then the delicate work began, carefully removing the masks using a razor blade, a steady hand, and some granny glasses so my aging eyes can see.



After the color is complete, a coat of clear is applied and force baked for 30 minutes at around 400 degrees...mmmm, smell that cooking?


A good sanding to smooth the texture, then its decals, another clear/bake/smooth, and finally the third and final clear ran really hot with double reducer so that it burns into the previous coat, evening any dry spray (orange peel) and giving a glassy finish.



The frame is baked again and finally finshed with a good rub down of 3M compound.

Then it's time to show it off!


Hope Roy likes it.


It's a shame that most indy builders don't spray their own stuff any more, I really enjoy tying the project together with a little eye candy to match the performance. It's very rewarding.


Catch y'all in a few days, I'm going to catch up on a bit of sleep!


cheers,


rody

Are we learning the art of framebuilding?

So that's the question.

It's been a bit amusing to watch the interaction on some of the more prominent frame building web sites in regard to how "new" builders learn the craft while the "old" guard fervently protect their adament beliefs.

What's the point of contention, you may ask?

The crux is...How does one go about learning the craft of building hand made bicycle frames.

See, a lot of the established builders have been blessed (a point that I strongly believe) with the opportunity to learn from an established master in an apprentice role. These present craftsman seized a rare moment in time when another was willing to share and guide the development of another. Techniques, tips, and dare I say secrets, were passed on in an environment that spawned growth and mastery. Experience earned through years of trial and error was given to the new assistant, expediating the opportunity for self reliance under a watchful eye. The value of such an education is difficult to qualify.

Flash forward to today...the cycling market went through some rough years where a lot of these small production shops have since closed there doors. Builders that have survived have done so by scaling back manpower, production, and financial exposure. Most operate independant one man shops with tight budgets and are protective of the freedom to self schedule and pace the work environment. This necessary down scaling has almost eliminated the ability to host an untalented apprentice who places time demands and attention away from the workload, requiring a greater emphasis on instruction.

So where can someone go to learn the craft? Often the answer is a formalized abbreviated course such as the one offered by United Bicycle Institute or Doug Fattics small group instruction. Such courses are an excellent introduction to the methods utilized to put together some tubing into a frame, but in no way certify you as a practioner of fabrication.

Here's where the crux emerges....the old school say's "Such courses expose the student to the process, they do not assist with mastery...only a long term relationship/work experience can do that"

The newbies say "How am I suppose to learn this stuff if I can't get a job anywhere, this is the next best thing."

Most of this has been a rhetoric review for those that browse the forums, but now I'm ready to get to my point.

I constantly have individuals emailing, calling, and stopping by wanting to know how to learn the craft of framebuilding. Most are ready to attend a class, may have even purchased their first tubeset, but have no idea how to go about it. This is what I typically suggest...

Put the tubes/lugs/rod/torch/dreams of riding your own frame in a week away and take a deep breath because what I am about to propose will take you on a journey of focus and execution and when you are done, you will not even have a frame to show off.

To truly learn the art of framebuilding, build a fixture first.

I know, it's not sexy, but there is no better way to fully understand bicycle design and fabrication.

The process of designing a fixture demands that you fully understand how a frame is put together, how all the parts interact and the physical relationships between them. A fixture must establish those relationships and be exacting to the highest tolerance. As if that was not hard enough, an excellent fixture design is variable, allowing for frame sizes from silly small to Amazon Women tall, and wheel sizes from circus tiny to Bigwheel big. Accuracy and repeatability are key.

In addition to accommodating a varied build profile, you must think through the fabrication process and design the fixuture so that it enhances your access and ease of construction, rather than impede it. Have you left sufficient access for all joints, does the fixture allow for easy rotation, multiple positions, and welding/brazing in the jig? Do you have sufficient set off to get into the backside of all the joints? Not an easy task to accomplish.

These are all considerations that force you to fully understand bicycle design and fabrication before ever picking up a file or torch. By the end of the process, you'll have thoroughly disected the design, fabrication process, and gained invaluable skills in metal craft. Armed with this knowledge and experience, you have set yourself up with a far greater skill set than someone who chose to build without a fixture or purchased one.

It is unfortunate that in most's desire to come to the end product, they cheat themselves of a process that affords an opportunity to learn so much that will facilitate a more enjoyable and efficient building experience.

You can buy a fixture...you can not buy the knowledge and experience that fabricating one will afford you.

Want to be a builder?

Be ravinous in reading, focused and detail oriented, methodical in exacting repitition, and of utmost importance, be an advocate for yourself.

Oh, and build yourself a fixture. :^)

cheers,

rody

A big ol round up for ya!

It's late Tuesday night and I'm winding down before hitting the sheets...been a busy couple of days and I've gotta get up in 4 hours, ughh.


I'm going to hit y'all with a collage of photos tonight with a few comments thrown in for fun to catch up on the last couple of days.


Saturday began bright and early with some component build work for the upcoming Handmade Bicycle show. As my office is becoming over run with parts for the show bikes, I thought I'd better begin getting some of them together. Below is a bit of the effort from Saturday...2 Rohloff wheels, a couple of Phil Wood/Mavic wheels, and a few Chris King parts thrown in for good measure.

Sunday saw a visit from the crazy fast man himself...Dick Akers. Dick stopped by to pick up his new Groovy Cross bike. This bike will serve as his winter ride capable of fast group rides, light off road cross fun, and as his long distance race bike. The build consists of some Luv Handles, 9 speed grip shift with carbon derailleur, Saint cranks, Phil Wood wheels and Mavic rims...Sweet! This bike is made to take the abuse that Dick serves out daily. Have fun my man.

Then guess who came strolling into the shop...that's right, it's HOSS. No, not the one from Bonanza, this one rides a bike :^) Hoss is the proud recipient of a freshly coated Slinghot fork that we replaced the steerer tube in. Now the 'shot is ready to launch.

Monday was like a vintage christmas come late...lot's of vintage frames that are scheduled for some structural work and new paint arrived. Can you name all these classic frames? Don't scroll down until you give it a try...answers below.

Classic steel left to right; Serrota T-max, Yo Eddy, Grove Assault, Yo Eddy, and a Hot Head bar.

Today I finished up Tony's Ho Down fork with three coats of clear. Yeah, I know, crappy pic but it was getting late. This fork utilizes a rectangular box crown, 1.0 inch blades and scallopped dropouts. This fork is destined for his Trimble (one of many :) ). Can't wait to see some build pics with it all finished.


While spraying the forks, I began work on my last show frame, a Big Wheel made with Columbus, Dedda, and custom drawn steel. This frame will use Paragon sliding dropouts which will allow for Rohloff, single speed, or geared use. The frame is a bit more utilitarian than the intensive work that went into Roy's Jefe, but will still have some nice touches like custom dual Rohloff cable guides.

I've posted up a few pics of working on the rear end for your enjoyment...I know sexy curves make me all hot and bothered!

Tomorrow, I'll braze up the rear stays, weld up the rear triangle and braces, and throw on some braze ons and she'll be fini!

I'm heading into paint Friday through Monday to jam out all these show bikes so I will be a bit tardy answering email and blogging as I'll be a bit focused, but that doesn't mean that I don't luv y'all. Perhaps I'll post up some in process paint pics...don't want to give away too much though ;^)

See you in a few days,

rody

A sweet retro/classic ride...

I finished up one of the show frames yesterday...don't want to give too much away but it will be a sweet ride in the classic mtb style. I've called on some friends in the vintage community and scraped together a pretty neat build for this one. Big props go out to Jeff Archer at First Flight bikes and my friends in the vintage community for keeping the flame alive. This one will be fun for me and those involved, I hope some folks who see it appreciate it as well.

I brought in an intern today, I had hoped for some cheap third world labor but decided to invest in our country's folks instead. Em will be taking on the important tasks in the shop; cleaning up chips on the mill and lathe, sweeping floors, and generally looking cool. Glad to have her...she's a straight A student, hip, and works cheap :^)

Attention OSHA...please note the required safety glasses, ear protection, gloves, and requisite sucker.

Going to be building wheels today for Dicks 29er and some of the show bikes. Got a box of uber shiny parts from Phil Wood, some bomber rims from Mavic, and some spoke lovin from the Swiss...should be killer.

Here's a random shop photo to stimulate the eyes...

Catch y'all tomorrow,

rody

I think the sun came up today???

Whew, long days in the shop.

You know it's been a long day when you've run through your Ipod twice, the battery died, and there's still more to do!

Today started in the shop at 0600 and I'm just winding down to go home (2200)...the family stopped by today to remind me what they look like...that was the highlight of the day for sure :)

Not sure if the sun came out today or not? Aw heck, it's Ohio, of course it didn't!

Well, Roy's Jefe took the final step before paint, a quick trip through the blast cabinet and now it's hanging ready for some liquid vibrance. I'll build the fork next week when I do some others for my show bikes and then I plan on four days sequestered in the paint booth to spray everything up. Anybody have any favorite scheme's that they'd like to see?

With Roy's frame completed, it was turbo speed onto some other work.

I got an entire frame almost done today, working like mad and burning my fingertips cause I was too impatient to wait for things to cool. Still have to put on a few braze ons and finish the dropout details, build a bar for it, and it's on to the paint queue as well.

Mike, of Sherrick Photography, stopped back with some images that he shot yesterday. Here's a cool shot for you to enjoy...

The wait list is growing quickly, I apologize that I have not had an opportunity to update the official list on the web site, http://www.groovycycleworks.com/ , but I'll get to it soon. If you are wanting a frame/fork/stem/etc... in the near future, drop me a line soon. I'm hopeful that I'll bring home some orders from NAHBS to fill out the year.

And the quote of the day that has been running through my head (don't know why?)

"Damn your black heart Barbara Striesand!"

Anyone know who said it? Loved that episode!

Til tomorrow,

rody