Hollow Leg’s Bikes (Mason Resolution, Dolan Tarck Bikes, Brompton, Local Framebuilder Specials; Fixed & Gravel)

Can’t believe you didn’t mention using the…butt checker! Best tool in framebuilding!

awesome. i really need to do this at some point.
i did a bit of brazing and metalwork stuff at college (over 20 yrs ago...) but haven't really done any since.
subbed and insta-stalked!

Ha! Can’t believe I forgot the butt checker!

Day two in the bag.

Started off with some brazing practice on a steel square tube followed by some offcuts of bike tubing. This was really fun. Trickier than expected but we were both improving each time we brazed some tubes together.

Next we finished off the front triangle by mitring the down tube. Matt does the compound mitre on the down tube by hand and watching him work a file was a sight to behold.

With the main triangle done we started on the chain stays. Matt had drawn up a cross section of our rear ends so we could see where our tyres and axles would sit in relation to the BB shell. From here we plotted the position of the cranks we would be using as well as chainring and dropout positions. We made mine have clearance for Omniums (if you can fit an Omnium, you can fit any track crank), and Gabi’s for a GRX 2x (even though she’ll be running 1x I wanted to have the option to run a double just in case). Gabi’s needed a cheeky dimple so we added that after cutting the stays.

Finally we did some more brazing practice on some tube off-cuts.

Some photos.

7 Attachments

Days three and four done!

Wednesday we started by mitring and slotting the chainstays. This took a wee while as we are both using slotted dropouts and Matt’s attention to detail goes above and beyond ensuring that everything fit like an absolute dream. Then Matt used a TIG welder to tack the chainstays to the BB and dropouts. We then popped a wheel in the dropouts to double check alignment and clearance. We also popped in a BB and crankset to check everything fit as it should.

Throughout the day we also practiced brazing bits of tube a few times.

Today we sorted the seatstays. First they were mitred on the lathe with a hole saw to fit at the seat tube, and then hand filed on the other end to fit the dropout.

Next we practiced brazing with some more bits of off-cut and then after lunch ensured all of our tubes and brass brazing rods were throughly deburred and cleaned using sandpaper and acetone.

Finally Matt tacked both frames together using the TIG welder ready for us to start brazing tomorrow morning. Now we have some frames!

It looks like the course will be running over into the Saturday but as this is the first time Matt has run his workshop with two people simultaneously he was half expecting that to be the case. We will be aiming to finish off the bosses on Saturday.

Some photos.

4 Attachments

Some more.

4 Attachments

Tig tacked? Interesting. I always thought it made sense to Tig tack a frame in the jig and take it out to braze but I've not been able to find anyone doing it and wondered why

Paul Brodie does it all the time in his youtube vids

Ah nice, been a few years since I've watched his videos. I remember him tinning the joints before fillets but hadn't remembered the tacking

I'm not sure I've seen him do it on a frame, but he does it a lot on stems, forks and other stuff.. Also uses masking tape as a fixture from time to time..

This looks like such a memorable and fun experience. Great daily summaries too. Was there a lead-in time for dialogue and agreeing geometries for your frames? How many hours per day are you in the workshop, roughly? Do you plan on making the forks too, or will they be carbon? Is paint/powder dealt with separately? So many questions, sorry. Half minded to book a session myself!

Correct, TIG tacked. I guess you could braze some tacks on there as well. I’m not really sure why it was done this way but it seems logical if you have the equipment.

I would throughly recommend it!

Matt is happy to help with the geometries based on current bikes, body dimensions, type of riding etc. Likewise he is also happy if you supply a Bike CAD and you work from that. We did a bit of to and fro via email for Gabi’s bike but I was pretty much set on what I wanted.

We started at 8am and finished at 6pm or 7pm each day. As there was two of us on this course and only one could braze at a time I imagine one person would be a bit quicker. There is also a ten day course where you hand file a lot more stuff!

We will both be using carbon forks but Matt is happy to make a fork during the course. I believe @Cupcakes made a fork while on this course.

Paint/powder is dealt with separately but Matt has contacts that can sort both if needed.

His framebuilding course is Scottish Framebuilders Workshop on Insta.

Day 5 and we’re done.

(Well, almost! We overran a bit so I’ll be going in tomorrow to do bosses and braze-ons.)

1 Attachment

Correct, TIG tacked. I guess you could braze some tacks on there as well. I’m not really sure why it was done this way but it seems logical if you have the equipment.

My opinion/thoughts,

I braze tack but you have to watch that you don’t disturb the tack when you start brazing for real coz your working with enough temperature to do so. You won’t disturb a tig tack the same because brazing isn’t (shouldn’t be) hot enough.

Also tig tacks are tiny so are well hidden by the fillet where a braze tack can be noticeable after completing the fillet.

Bravo, good work you both look so chuffed.

Paint/powder is dealt with separately but Matt has contacts that can sort both if needed.

Please paint them. Powder is (imo) a horrible way to treat a frame, especially ones you’ve worked so hard on. Again in my opinion, even painting them yourself with rattle can primer, paint and lacquer is preferable to powder as you can use a primer with anti corrosive properties which powder (generally) has none of.

Matt has a contact to get frames ed coated for corrosion resistance which would be well worth while if you have the budget and can wait the week or two for it to be done.

impressive stuff, looks like an amazing experience.
are you left to your own devices to clean up the frames prior to paint? cleaning up the fillets etc?

Fun times

This is what my instructor said when I was learning to braze to teach the sixth formers! I can tell them I learned it on an online forum now 😂

Curious btw, why is powdercoating not good? I know Stayer coat theirs and it’s a nice lustrous finish, but I’ve heard others express their dislike too.

I'll also vouch for Matt as a top, top guy. He did a great job on the repairs on our tandem and was very communicative: https://www.instagram.com/p/C5J3roaMP7_/?img_index=1

Wouldn't you just start at an opposite end to the tack? So then by the time tmits affected by the heat, there is already some brazed tube to hold everything in place?

I’m going to do it. Will drop Matt an email soon. It’s not that I need another bike (who does, really?) but that the experience would be brilliant and a rare opportunity with the upcoming sabbatical. I googled around and Matt’s pricing is very competitive compared to other (London-based) framebuilders.