Hulsroy's Hustle

How was that section of stay removed?

2nd cut half round file :)

Edit: Plus patience

Now on to forks. I am working on a flat mount jig...

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@svenhöek

Is this 160mm flat mount?

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Go one better and design it to mount a flat mount caliper without the adapter plate?

Would that not mean a bolt from the front side through the leg?

I suppose it would. I guess that’s why it isn’t done on otp forks

Open have done it but carbon obviously

I am not sure that looks much better tbh, But I will think about it as the dropout vs lower bolt on adapter plate is actually causing issues.

It is both because the adapter can be reversed for 140/160. Shimano sometimes make smart stuff.

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Recessed bolt head and it would look good.

Aha! Genius. I have never had flat mount my self.
I will have a look at how to do it with bolts from the front.

...

...

Sometimes I fuck shit up. It is a part of making and I do it regularly and I normally don't bore LFGSS with it, but this time it is big enough of a lesson that I thought I'd share it.

Building @JesperXT's frame was the first bike for me on my new self made jig and the first bike in two years after I moved to the UK. Jesper and I had been chatting about the frame since forever and I had a precise list of his wishes and specs.

The bike took almost a year to finish as I have been making fixtures for different things and doing it after work.
Somewhere down the line I lost the list but thought I had it all in my mind. Having build a couple of frames with Sam at Stayer I felt confident that I had my shit sorted out. But in reality I didn't.

I rushed to finish the frame as I wanted Jesper to have it in time for summer season. I sent it off to paint and got Stayer to box it up and ship it to DK...
And couple of weeks later @JesperXT discovers the horror. I had forgotten 2/3 of the mudguard eyelets I promised and I hadn't attached a cable stop for the rear mech. So along with some pin holes that needed fixing and a rear bridge that could do with some re-positioning the conclusion was that he had to sent it back to the UK for me to fix it.
I did that yesterday. This is a good experience for me and the whole point of making frames for my friends before potentially going into business.
At first I was embarrassed but now I am actually proud of the frame. It has been hard work and frustrating but the battle is totally worth it.
For future builds I will take my time (I am not a pro and don't make money doing this) and I will check things twice and have a digital checklist.

Lifesaver for hidden eyelets you forgot:

"Custom" drill bits:

Obviously it needs powder coating again.

You live and you learn. Thanks for sharing!

Respect for sharing! Still looks awesome

Dibs being your first apprentice :)

Yes! I love mistakes

Thank you for the insight. Enjoying your thread

Dibs on frame,if he sends it back again :)

About the cargo thing,
these cable thingy sounds awesome but seem difficult to master.
Dear Susan busted his at Concours de Machine.
Maybe spying on the Douze would help?

Well, difficult is what makes it exciting. I am not a big fan of the Douze's tensioning system (without having seen one up close yet) it seems that their system is based on barrel adjusters. And in my mind they ALWAYS seize on bikes. Having to barrel adjusters close to each other makes the. Hard to use and offsetting them (on my design) looks clumsy and adds unnecessary weight.
Hence why I moved away from them again.

I want as little threads on the frame itself and I want everything to be non-proprietary and fixable in rural areas. But I am still thinking and I will solve it. I just need time.

WOW! superb! i envy you!

ta.

Looks like a thingy similar to a chain tug with barrell adjusters.

You could do something similar with a slider and something akin to a b-screw so that there's no actual thread on the bike? Just something for the adjustment screw to butt up against...

Yes. That is not half bad actually.