The bicycle is the most civilized conveyance known to man. Other forms of transport grow daily more nightmarish.

Only the bicycle remains pure in heart.

~Iris Murdoch, The Red and the Green

about

in the summer of two thousand nine, i built a bicycle. i designed it...

i built it...i assembled it...

i rode my bicycle.

and i loved it.

index

project introductionfabricationcomponentspowdercoating

151720

annual maintenance cost

cars vs. bicycles

project briefThe simplest solution is usually the best one. the fixed gear bike is no exception. it is lighter than a road bike, a better training bike, and costs less to build and maintain.

kiss: keep it simple stupid *U.S. Bureau of Transportation Statistics; Moritz, 1997

$300$300

$8600

02

riding a fixed gear on the road is excellent exercise. When you need to climb, you don’t need to think about when to change gears, because you don’t have that option. Instead, you know that you must just stand up and pedal, even though the gear is too high for maximum climbing efficiency. This makes you stronger.

-sheldon brown

1. 50% reduction in the risk of developing coronary heart diseases 2. 50% reduction in the risk of developing adult diabetes3. 30% reduction in the risk of developing hypertension

MEASURE TWICE...

CUT ONCE.

rider dimensions

arms.........58cm

torso........65cm

inseam.....78cm

height.....173cm

weight.......68kg

MEASURE

CUT ONCE.

58

CM

65

CM

78

CM

torso measurement + arm measurement

2.3= 54cm

inseam measurement X = 53cm.67

04

geometrythe frame was designed to be short and steep for responsive steering, as well as a stiffer ride. the short and stiff rear triangle transfers power the ground more effi ciently...for sprinting power.

ground more effi ciently...for sprinting power.

54CM

53

CM

72 head tube

73 seat tube

After measurments are taken of the rider, The frame style is decided. In this case it will be a track frame with a fixed chain drive. A CAD program is used to translate the measurements into a geometry, and then the dimensions of the tubing are taken into account for, In the end, a 1:1 scale drawing is printed and used for reference during the

build.

cad drawing 1:1ashlar vellum graphite

researchframe stylegeometry

in the beginning

06

4130 chromoly steel tubing

big buttes the tubing for the frame is double butted. the ends are thicker than the center of the tubing. this ensures that the tubing is strongest at the points that receive the most stress...the joints.

cast steel lugs

Each piece of tubing is

double butted, which

makes trimming each tube

a bit more complicated.

Length is taken off from

each end to preserve the

variable wall thickness.

partslist

08

down tube

seat tube & bottom bracket

head tube

cast steel lugs

top tube

look@the big picturethe full scale drawingis used as a guidethroughout the buildto make sure everything is done accurately, and within the acceptable rangeof tolerance alloted.

coldfitting

double checkEach frame tube was cut to length and mitered to fit nicely with and against the other tubes. The seat tube is the the first tube be brazed onto the bottom bracket and seat post lug.

vent holes are drilled and then all tubing is prepped in a solvent bath to be prepared for brazing.

of tolerance alloted.

10

i brazed a frameonce the frame had cooled enough to be held, we took it out of the jig and soaked it in soapy warm water. this loosened up the fl ux that had hardened onto the frame. a little bit of time, a wire brush,and some elbow grease were all it took to get it to this point.

oxy acetylene“pull the silver”once the lug is hot, silver is feed into the lug at the edge it meets the tubing. it is then dragged with the heat to spread it about the entire jjoint

12

jigged upa magetic compassis used to find the correct head tube and seat tube angles before securing the jig down. flux is added and then the joints are brazed one at a time.

i brazed a frameonce the frame had cooled enough to be held, we took it out of the jig and soaked it in soapy warm water. this loosened up the fl ux that had hardened onto the frame. a little bit of time, a wire brush,and some elbow grease were all it took to get it to this point.

mock upAfter the frame was done being brazed, it was test fit with a set of 700c wheels and tires...tolerances were all where they needed to be.

it is now time to start sanding, filing, and cleaning the frame to prep it for powdercoating.

14

i brazed a framethis is a picture of the frame shortly after fi nishing with the brazing. at this point i had started cleaning up the frame, but mostly the joints. The lugs were fi led to keep a nice edge between them and the tubing.

“can i borrow your wheels”? luckily for me, a friend was willing to remove his wheels so that i could see the frame start to come alive. thanks again Tyler.

hours of preperation

over one hundred hours were spent on the frame before sending it out for powdercoating. emory cloth, fine tooth jewelry files, and scotch bright pads were used to keep a square edge between the lugs and the tubing.

100

16

my kitchen floorthe scotch brite pad was a good friend of mine in the final stages of preparing the frame for powdercoating. becuase of the oxidation, this was done at the beginning and end of every session.

easton low rise handlebarsoury mtb gripsvelo orange polished stem

steering

MKS sylvan tracksoma strapssoma cages

pedals

sugino rd 170mm cranksoma 16T cog47/16 gearing1/8” gold KMC chain

drivetrain

components

18

seatingsoma kamisoribrown leather

origin8 seatpost

wheelsweinmann DP18

origin8 hubs3x lacing

soma everwear700 x23C tiressugino rd 170mm crank

soma 16T cog47/16 gearing1/8” gold KMC chain

“did you make that?”

I got a lot of compliments on the street with this bike. Old and young people were drawn to this bike. The photo below was taken by a photogrpaher on the streets in san franc is co. Thanks again Scott.

20

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duboisdesign

duboisdesign

duboisjosephdubois53@gmail8452347083industrialjosephdubois53@gmail8452347083industrialdesignjosephdubois53@gmail8452347083

design1188missionstreet1621sanfranciscoca94103josephdubois53@gmail84523470831188missionstreet1621sanfranciscoca94103josephdubois53@gmail8452347083

crime sceneThis is the last place that my bicycle was seen alive. while in the building next door, in front of a window...my bicycle was stolen when i was turned. The lock was cut and it was taken from me in broad daylight. I have not yet given up hope,

...the search continues