GT Edge Aero TT --> paint pron tarck conversion attempt

I don't know how to weld but I'm pretty good with a hacksaw?

Well, I have a hacksaw...

Your hired.

Sweet, I'm a dab hand with an angle grinder as well, what could possbly go wrong?

Did this ever get posted in this thread? Saw it in the Uve bin Indra'd thread a while back

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Didn't someone suggest a lufgus tshirt with it on?

Yup. Shame they never got made

It's the way forward....

http://www.ebay.co.uk/itm/SUPERB-CUSTOM-BUILT-FIXED-SINGLESPEED-TRACK-BIKE-/332088820472?hash=item4d520942f8:g:WUkAAOSw-0xYdfHW

That is incredible.

Baby blue and everything

Those are some superb custom drop outs!

One brake, no levers

Can't stop, don't want to either.

hey dawg do you want some horizontal dropouts on your horizontal dropouts

Someone plez make horizontal dropout version of this..

The FAKE NEWS lfgss (failing @TM @Thrasher @pdlouche) Is not my enemy, it is the enemy of the people!

We are doing this, and we are doing it BIGLY.

We are building gussets and we are building them so fast...they are going to be so big. And YOU are going to pay for them!

It lives!

Gussets to keep the logic and rational thinking away from this build.

That turbulent air is full of bad hombres.

I jest x

Ah, the prodigy returns. Relief washes over me.
Lets see the gussets then!!

#teamjdmitch

Hazzahhhhh

Well, when we last left this project, I was at the stage of stripping the paint in order to sand down the welds and attach the gussets into a lean mean aero machine. Luckily I love the smell of nitromors in the morning:


however by the end of the day, I wasn't getting anywhere so I decided to buy the real deal: 5 litres of 99% pure dichloromethane. When it arrived, I realised:

1. this chemical is incredibly toxic and can't be done anywhere near my baby girl (only a few months old at the time)
   
2. it is way too thin (liquidy) and evaporates too quickly to actually stay on a surface of the bike long enough to react with the paint so it can be stripped off.
   
   

So my solution was to cover the bike in rags soaked in the dichloromethane, and then wrap that in cling-film to keep the chemical on the surface of the paint as long as possible:

finally after a while, I got most of it off, with the help of a wire brush:

Then the fun really began of removing the braze-ons and smoothing out the welds. @TM let me borrow his hacksaw:

the laborious process of sanding the welds down was just too boring, and things got bogged down, and I kind of gave up / decided I was done enough to cover everything else with bondo. So I finished cutting the gussets today:


If you remember the poll from a few pages back on the different gusset options, the collective wisdom pointed me towards one on the ST-DT junction, and one on the TT-DT junction. A further filler area between the seat stays, seat tube, and brake bridge has some insulation foam inserted here. The final step before it got too dark was fixing these in place with Sugru so that I can start filling in with bondo tomorrow:

I also did a bit of filling in on the dropouts with aluminium bar, but its still far from pretty, so I will withhold pictures of it until it is slightly more presentable. The dropouts/struts, and the foam insulation gusset will be fixed in place properly with this really, really ridiculously good looking product:

Then a bit more aero-ing with bondo, and bob's your uncle: we're ready for the paint!

I am so glad my persistent begging has paid off, really happy to see the progress. We've all finished grieving for the frame now and I for one am excited to see how it works out. This could be @Polka_Dot aero helmet level of win (with less science and more bondo)