Not too long ago, I used BikeCAD to draw up a frame which I believe will fit me well, and based it around a 120mm fork, single speed drive train, and 26-inch wheels. Using the numbers from the technical drawing, I called up Nova Cycles and ordered up a stack of tubing to get the job done.

So, here you have a bicycle
--> Some Assembly Required
--------> no instructions included.

I've always found that having the right tool for any given job makes doing things right that much easier, so I've picked up a TIG welder, and a good frame jig to help me through the process. These things will make a lot of it easier, but I am still doing all of my tube mitering by hand with bastard files and a dremel. Although with the miter templates generated by BikeCAD, it is also much easier to accomplish good miters as well...

Here are a number of photos of the process:

Top tube, with miter templates in place, laid out on the full size drawing.



Tob tube miters in progress, hand files, bench vice and wood blocks. Primitive but very effective.



Top tube / head tube junction mitered and laid out on the drawing.



Top tube, seat tube, head tube and bottom bracket fitted up in the jig.



Close up of top tube / seat tube junction.
As you can see, I have managed to get the seat tube and top tube mitered at this point, and will be proceeding on to the down tube in the very near future. I'll write another installment at that time, until then... go ride your bike.

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