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67 Framebuilding Steps with Paul Brodie

May 17th, 2013
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Want to be able to build a frame like Paul Brodie? Follow this handout Paul has devised for his framebuilding 101 course and it’ll give you a start. Better still of course attend one of his courses :D

The PROCESS:

1. design frame
2. full scale drawing
3. select tubing
4. mark DT for butting
5. mitre DT for BB
6. NS / Tig DT to BB
7. align DT to BB
8. setup main triangle jig
9. option: ovalize top of DT
10. mitre DT for HT, deburr
11. check DT / HT fit on jig
12. mitre seat tube; notch for DT
13. drill water bottle holes on DT and ST
14. mark TT for butting
15. mitre for HT, check fit on jig
16. mark mitre for the ST, ovalize TT if needed..
17. mitre TT for ST
18. assemble tubes on jig; check all mitre fits and adjust if necessary.
19. sand / clean all areas of tubes to be joined
20. re-assemble on jig
21. tack frame in jig using NS or Tig
22. remove front triangle from jig
23. Tig or NS / FB TT to HT
24. Tig or NS / FB DT and ST to BB
25. align DT and ST to the BB
26. align HT and ST on the surface table, allowing for future weld pull..
27. Tig or NS / FB DT to the HT
28. align HT and ST on the surface table, allowing for future weld pull..
29. Tig or NS / FB TT to the ST, and file up all FB’s
30. check HT / ST alignment once more
31. S/S water bottle BO’s
32. S/S cable routing BO’s
33. face HT ends
34. slot ST
35. drill hole and deburr
36. inspect front triangle. Congrats! You have built half a frame..
37. mitre CS for BB
38. mitre CS for DO’s
39. option: indent RH CS for chainring clearance
40. prep dropouts
41. assemble in CS jig / check tire clearance
42. Tig tack / NS CS to BB and DO’s
43. remove from jig
44. check frame against drawing
45. Tig or NS / FB CS to BB
46. face and chase BB threads
47. align DT and ST off BB
48. align HT and ST on surface table
49. align DO’s with HT and ST
50. mitre CS BT
51. NS BT between CS
52. align DO’s with HT / ST
53. bend SS
54. mitre top of SS for ST
55. mitre SS for rear DO’s
56. Tig tack and NS SS to ST and DO’s
57. NS SS to ST
58. Tig or NS / FB SS to DO’s
59. mitre SS BT
60. NS BT between SS
61. Tig or NS canti bosses or disc caliper mount
62. SS all remaining BO’s
63. ream ST to 27.2mm
64. align DO’s with HT / ST
65. option: align DO’s with the Campy tool..
66. stamp serial #
67. final frame inspection
Congrats on finishing your frame. Thanks for taking the course! PB

The LANGUAGE:
ST seat tube
DT down tube
TT top tube
HT head tube
SS seatstay
CS chainstay
BT bridge tube
BB bottom bracket
NS nickel silver
S/S silver solder
FB fillet braze
BO braze on
DO dropout
PB paul brodie

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