Benana's bikes, attempts at frame building and bag making

From the photos looks like went on to braze on the dropouts on the fork.

And then for maybe my finest moment. I drilled the blade for internal routing for dynamo wiring. With the holes being on different planes of the fork and with quite a lot of rake it was a right pig. I spent 15 minutes not being able to feed the internal tube more than 2 inches. I thought I had without a doubt fucked it. Some how with lots of wiggling and sweating I managed to get it fed through the second hole. I was chuffed to say the least.

3 Attachments

A much easier routing for brakes and holes for bottle mounts.

Then brazed the blades into the crown. Even with the jig I need to do some cold setting to get the wheel central. That is apparently normal or maybe the book is just being nice.

3 Attachments

On the fork I used a brake mount from ceeway and thought to make it match would use the same on the rear. It was never going to fit so I made this wonderfully agricultural one. Planning to change it when I have more time.

Without a proper jig I sourced an old rotor and caliper. I didn't think the caliper looked up to the job so used the real thing. I was pretty nervous about putting my new expensive wheels in the firing line but without any other options I went for it. In the end it was fine for the quick tack. I removed the wheels to blob on as much brass as possible.

5 Attachments

Added the necessary braze ons for all your touring needs as well as drilling my bottle cage holes on the piss.

5 Attachments

Missed out the step where I attached front and rear. I managed to get head tube and seat tube bang on inline. And the correct angle between down tube and seat tube. After brazing it had slackened off a degree. Bit annoying but it was still all nice and plane. Maybe should have taken it apart and re done it but didn't fancy trying with the deadline. The bike has a pretty slack head angle now, looks like an early mtb now which i'm not totally against.

1 Attachment

Nice read! Keep it up

Thank you!

Awesome work, really coming together. I like your fixturing setups, always look simple and effective.

Thanks! It was really useful having the extrusion. Can be reconfigured for different uses and although a little fiddly to set up a good way to do it without dropping a lot of cash on a more professional set up.

Going to try keep this updated a bit better.

Got some new bits for my first frame. Changed to mini v's as I was getting a bit of chatter from the front brake and they didn't stop as well as I wanted. Bit of a shame because they looked cooler.

I wasn't getting on with 44cm bars and a mate at work gave me some he wasn't using. Only a little smaller at 42 but still allows me to carry systainer tool box on the front. They also came with the old tektro brake levers which look sweet.

Pretty happy with it so far. Still trying some different length stems to get it spot on. Eventually want to make my own with built in spacers.

2 Attachments

Today's job is taking the front wheel apart and lacing in a new dynamo hub. Just went for a cheap shimano one from sjs but as this is meant to be a bike that I can not be precious about, it should do the job nicely.

1 Attachment

Bags as well aye!? I couldn't do any frame building over lock down, so had a go at making some bags. Made this one a couple months ago and is probably my best.

I didn't have any colours that matched the frame exactly so went for a bit of a clash. Ended up going for pink but tried not to make it to girlie.

Had to leave space for using the downtube shifters but it's still big enough to get a lock and bits in.

2 Attachments

Awesome, bags look great. Ive done a few but mine dont look that good hah. I like the way of attaching to the tt with the string, might have to give that a go

More pictures of this in the gazelle thread please!
Been meaning to ask of you could make a lairy pink saddle bag for another bike I’ve got - your frame looks great as well 👍🏻👍🏻

I bought an industrial sewing machine for cheap and that has really made a difference. It doesn't struggle with multiple layers of fabric, although I struggle with the speed, it is fassstttt.

The string is how all the pro's seem to do it. It does spread load more evenly and you don't catch on prickly Velcro.

I'll get a better photo of it first. My girlfriend has it set up more as a town bike, pretty sweet still.

Definitely, I have plenty of pink fabric except my machine is at my parents. Hopefully i can bring it to London soon.

The wheel build took longer than expected, not helped by only having a multi tool spoke key in the house.

Currently mid way through setting up the lights. Gave the rack a quick rattle can of black and is currently drying on the boiler. Paint was a bit soft to go back on the bike.

Sorting the rear light cable routing tomorrow and it should be good to go.

What happens if I don't earth my rear light? It says to do it in the guide I was looking at. I guess it's easy enough so I won't skip it,just wondering.

Said I would make a mate a new fork after he bent his riding off a double curb. He had a 1" threadless so was struggling to find a steel replacement.

2 Attachments

I've started renting a desk space in a workshop so can now do some more frame building after not having anywhere to do it for a while.

Decided to braze the crown in with brass as it wasn't a very tight fit and I have pranged myself out that it won't be strong enough with out. It took a lot of heating but pleased with getting it too flow nicely.

3 Attachments

Dropouts today and again felt the need to do it with brass.

3 Attachments

Sweet!

The blades were a snug fit so I was happy to do that with silver. Think I tend to get scared I haven't got it flowing enough and use too much heat. Need to work on this.

After brazing got it all trued up and nearly about to face it but it turns out my mate has got a new frame. So no need for this. Good practice though, been watching the Paul Brodie youtube vids and good to give some of his techniques a go.

1 Attachment

Today I made a start on fixing up a genesis equilibrium with rusted stays.

Plan is to put track ends on and give it more clearance. Then I will transfer the bits over from my current road fixed. Options for 'tracklocross' maybe in summer.

Because the fork I have has a bigger a2c than the spec, i've drawn it all out to work out how much I need to lower the dropouts to keep the original angles. Hopefully it works well as it will give me a bit more clearance as the equilibrium is a road frame, so bb might have been a bit low.

4 Attachments

Awesome, looking good. Ive wanted to build a set of forks for ages, but havent got round to it yet.

I guess a steel forks suit a more functional role. You'll have to build yourself a touring bike or similar.