How to Build a Bike in 4 Days: This was the second, and final, attempt at nailing down a the perfect frame with David's custom geometry and 3.0 Knards. It was a big (sic) challenge, but given the outcome of the last frame (BB too high and TT too short) and I had my reservations on the final product. Alas, I actually had the privileged to ride it yesterday, and it feels perfect. David commented that it rode so smooth on the road that it felt like a road bike. That was the idea! I'm stoked.
Since the first frame was off (it will actually fit me perfect 26" winter tires, more later...) I had to push to get this into the painter s soon as possible. With the last of the parts coming in on Thursday and the painter scheduled for Monday, that meant 4 days to put the whole thing together, start to finish.
Day 1: Pulled out the drawing sheet and rough cut all the tubes. Laid out the master drawing and 
mitered the main triangle, with the help of the new tube notching clamp I picked up on sale. I also mitered out the chain stays and fork blades, mostly by hand, with a little help from the mill. Once everything fit together properly, I tacked it in the jig and welded most of the front triangle and fork.
Day 2: Worked on the rear Triangle, cutting, mitering, tacking, checking, and welding it all together. Given the complex geometry from the oversized tires and spacing, this took lots of measuring three times and mocking up tire clearances and spacing. But, It turned out great!
Day 3: Finished welding the fork joints, and disc tab. Mitered bridges,
created the custom dog leash loop,
welded them in, then marked and cut all of the braze-ons.
Day 4: Brazed in all of the accessories; front and rear rack, fender, bottle and cable mounts, cleaned up the joints, and checked final alignment. All within tolerance. Tapped in the serial number. DONE!
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