Building the Black Ship Monster X Cross with Campy Athena EPS

Oh bother. This post was started months ago and got erased in the cyber-nethers. Let's crack a beer and see what happens:

Unassuming pile of Chromoly tubing

Monster X Cross

 (Or how to turn an unassuming pile of chromoly tubing into a sweet ride)

Design and Drafting: David and I collaborated on the design for this one. As an avid rider and owner of many custom bikes, he could tell me exactly what he wanted out of  the frame. in this case, fast, aggressive but still comfy position in drop bars with Campy Athena EPS.

After drafting the soon to be frame, the appropriate tube set is ordered. in this case, Nova Cycles made a custom Monster Cross kit for Black Ship Cycles that used lighter 29er tubing with the same rear triangle as the Icebreaker.

Part 1 - Cutting, Fitting, Welding: Once the tubing showed up, the cutting and filing began. Rough cutting main tubes began with a chop saw, then mitered with bi-metal hole saws in the vertical mill. Once the tubes were notched, I perfected the fitting by hand filing and cleaning the joint. This was also a good time to drill out the enlarged bottom bracket holes to accommodate the electronic shifting wiring.

We marked all of our spots for the EPS wiring and drilled them out, then cleaned'em up with a hand file. This took a while, as neither one of us was very familiar with the group, but we found all the info we needed and it was a rewarding accomplishment to put a sweet custom spin on this bike.

As soon as everything fit up properly and snug in the fixture, the front triangle is tack welded into place in sequence.

The piece then comes out of the fixture and onto the table for the finish welding, also done in sequence to prevent heat warpage and misalignment.

Once the front triangle is check on the alignment table, the rear triangle gets cut and fit, same as the front. The tubes are slotted for dropouts using a rotary cutting wheel and hand file, then the dropouts are inserted and aligned. Everything is tacked in the frame then welded in sequence on the table. The frame is then checked for alignment and clearance.

The next step is to cut, fit, and weld in the fender mounts. After that, the brazing will begin.














Part 2 - Brazing, Finishing: First, all of the brazed on small parts get dry fit and marked on the frame with sharpie. Holes are drilled for threaded mounts and other mounts are filed to match the curve of the tube. Once they are all set up and clean, each piece is clamped, fluxed, and brazed into place with either silver or bronze using an oxy/acetylene torch. The flux is cleaned of and all braze-ons are thoroughly checked, any adjustements are made.

Finally, the seat tube is notched and reamed, any inconsistencies are filed down, then the final alignment and quality check is done. Once everything passes inspection, it's off to the paint shop! 

The Monster X Cross!

2015 Winter/Spring Prices

2015 Winter/Spring Custom and Repair Menus!

We updated the pricing to reflect changes. Of course, we aim to keep prices affordable and accept payment plans as an option to get you the frame that is just right for you.

Our mission is not to make only the most exclusive and unobtainable custom frames, but to make superb quality, lightweight, custom Minnesota handmade frames an option available to the more and more Minnesotans that are serious about not only biking and commuting, but also the precision machines they choose to ride on. True Minnesota Craft Bikery.

Here's to 2015! Define your ride!

-Black Ship Cycles

http://www.blackshipcycles.com

http://www.blackshipcycles.com/custom-frame-menu.html

#blackshipcycles #craftbikery #mnhandmade

ICEBREAKER with 26" x 2.25 tires

I finally got this build put together!

I'll post a demo of the dog leash loop asap.

Morgan (our aussie-collie) loves riding through the snow! The bottom bracket is high enough that I can still pedal with him through 3-4" of soft white fluff, and plow right through snow banks.

Right now it is a frankenstein of parts from my shop and the salvage yard at the HUB Bike Coop.

1x9, SRAM X5 Der, GXP BB, Tektro Lyra discs w/V-Brake levers, 26" Bontrager Disc Wheels, 2.25" Bontrager Jones XC Tires.

So fast, so sweet...

Back In Action - Jamison's bed trailer - Part 1

   The weather is finally cooperating with spring, and that means the shop is once again bearable to work in. I've been hitting it hard this weekend breaking in the new heavy duty tube bender.
   These tubes will soon be a trailer/cart for Jameson. We spent the winter months biking through feet of snow to meet up and draw out the design, and its mostly ready to put together. It'll be similar to his original trailer, which he brought to me in pieces, but stronger and more durable to stand up to months of summer touring in all terrains.
  The original was an aluminum 1" square frame (cracked) with an aluminum bed and 16" (bent) thru axle 'cart' style wheels. The new custom one will be the same size, built tough with 1" steel tubing, reusing the aluminum bed, and converting the frame to duo dropouts to accommodate heavy duty bolt on 20" ryno lite bolt on wheels. the hitch? stay tuned..!

Finished: Custom Speaker Racks for Tipsy

Did you see these new racks on Tipsy Bike at the Bill Murray Mobile Dance Party?

Mpls, MN - Even if you did, you probably didn't actually see them - they were holding 25lb speakers to the front of the bike all night, like a pair of fkn champs.


 
The back story:
  We were working down the wire, and I mean it, to have them ready for the ride. I worked into the night, woke up early, had some coffee, then proceeded to cut and weld all day.

   As the paint was drying, I affixed all the hardware and waited for Tipsy. Due to technically difficulties, they didn't have time stop by and attach them, so after working all day and night for 3 days, I dreaded the call saying "I don't think we have time to attach them, meet up at the Nomad"

   I was still reeling from the feeling of dissatisfaction with not having them on from the beginning of the ride. That would mean 50lbs less of bumpin power. I couldn't fit them on my bike and get there in time to affix them and ride...

   Nat got home after work and agreed, the party was to be big, the job too big to fail; it had to be done. She offered to help load up her car and let me drive them, and my bike, to the park to set the up before the ride left. So she pulled around to the shop and we loaded everything up asap and I made it there just after Tipsy and with help, and lots o' sweat & elbow grease, got'em hooked up, tested, and bumped that fkn ride!

Thanks Tipsy for an awesome ride and stay tuned for lots more pics! (i took about 30-50 alone)

Interested in your own set or other custom bike gear?

frames | racks | mods | wtf

hit us up:  blackshipcrafts [at] gmail [dot] com

MIA Bike Night!

 I wasn't formally invited as a frame builder, but I did stop in (and sneak the Maiden Voyage in) to see what the local builders have been up to. here's a little gallery from A-Train, Wyganowski, Speedhound, Peacock Groove:

We also had a little HUB tent to to quick safety checks and small adjustments./repairs, and Tick brought Tipsy Bike out to blast some jams. Good conversations and lots of hot bikes, we took to the streets as Tipsy blasted jams down Franklin Ave to our destination for wooden nickel night and jams on the sidewalk!

This year was fun, but next year I hope for an Alley Cat beforehand and movies again (last year's movies were awesome) See ya next time!

Roody's Lugged Frame - Part 3: Finishing & Painting

Its finished! This lugged tour is going to get him, his dog, and his gear all the way up to New York and back (and hopefully more!) How did we finish it?

    Okay, where did we leave off? Right, braze-ons.

Brazing Frame Additions:
    The braze-ons I ordered from Nova (at a RIDICULOUS shipping rate, might I say) spent a few days meandering from California before reaching us in north Florida. Luckily, all of the pieces we needed were in the package.

   First, I check everything for fit, and scribe the miters on the rear brake cantilevers. Next, measure and mark the positions of all of the bottle cage mounts, cable stops, shifter lever bosses, canti brake mounts, rack mounts, fender mounts, chain hanger and cable guide.

   The cantis needed a little adjusting, so I opted to clinch them in a vice jig and file them with a half round, since there wasn't much metal to get through. Everything else was clean and ready to go.

   To hold the parts in place, I took a metal spring clamp and drilled and tapped one side to thread a bolt into. I also made a wood & metal jig to hold the cantis in place at an appropriate spacing (75-85mm) while I tacked them on.

    All I had available was a stick welder, so it was a bit splattered, but it worked.

We started with the bottle & rack bosses, since they did not require a clamp to stay in place. Next,  I used my modified spring clamp to secure and braze on the cable stops, chain hanger, and shift levers. I ran out of silver, and switched to some brass rods I had that were not ideal, but worked fine.

   We filled the gaps in the cantis and the fender mounts/braces. and touched up any spots in the lugs that needed it. Now that we felt like everything was sufficiently attached and all the gaps were filled, we started the cleaning and painting process.

Cleaning:
   Roody got on top of sanding and buffing the frame. He hit all the spots were filler metal had pooled and any splattersor other imperfections. Next, he wiped it down with alcohol to remove and oils or other contaminants in order to prep it for priming.

Painting:

   Went way better than the Maiden Voyage. We started with a self-etching metal primer. two thin coats. Then it dried and cured overnight. In the morning we lightly sanded that first layer, then added a second. Once that dried, we put on a few coats of satin black metal specific paint. We let it dry between coats to get some buildup. After those layers dried, we set in with a super hard flat clear coat, also made specifically made for metal. Everything sat really well, so we added a couple of decals and a few more coats of clear, then called it done and let it cure for a day before touching it. It looked great, and seemed like it had adhered better than the lacquer paints i tried on the first frame.

SUCCESS! It's finished. Check out the pics and feel free to comment or email if you have any questions/comments, including requests for custom frames and or trailers!

sorry this post took so long! i've had a bunch of problems with blogspot not loading photos AND not saving work several times and losing hours of typing and layout! hopefully i'll have better luck in the future!

Roody's Lugged Frame: Part 2 - Brazing the Tubes

Day 2: Brazing the front triangle

    After prepping all the tubes and lugs I checked all the fittings. You basically want all of the tubes to fit tightly into the lugs, but one that can still be pulled apart by hand. That way you get the tightest fit, with enough room to get a good amount metal in there to secure the joint.

    I put on some music and set up the brazing torch. I find it is good practice to take down and re-setup your torch every once in awhile. That keeps you aware of any problems with hoses or fittings, and helps you remember where your gauges should be set. The oxygen should be around 5 psi, and the acetylene/propane around 10 psi After checking all my fittings and pressure gauges, I grabbed my gloves and goggles and fired up the torch.

Getting the flame you want is pretty easy; barely open the fuel side, ignite the fuel, adjust until there is no gap between flame and tip, slowly add oxy, adjust until you have a whitish inner cone with a rounded (not pointy) tip, and a larger transparent blue flame surrounding it. [Need more help? Check out brazing vids on youtube]

   Starting with the seat tube and bottom bracket joint, then the head tube lug and top tube. once those were secured, I could put the rest of it together and align it on the bench. Once that was all in place, and aligned well, I set it up in the stand. One by one, each joint was separated, flux, and put back together.

  After double checking the alignment, mostly by eye, and a little with a caliper, I brazed the rest of the joints, and finished the front triangle.

   After putting the fluxed joints in a water bath, and cleaning up tools, I scrubbed off the flux with a wire brush.After re-checking the alignment, and being happy with it, called it a night.

Day 3: Rear triangle

Roody came out to the shop for the next session; fitting, aligning, and affixing the seat and chain stays.

   We started by prepping the pieces, then bending the dropouts slightly to curve inward, and set up the rear triangle. Everything fell perfectly into place on the bench. We used an old rear wheel to hold the dropouts in place, and a piece of plumbing strap to hols the seat stays in place. After checking the alignment, brazed it all together, bathed and scrubbed it.

   The basic frame was finished! Now to order the braze-ons!

[to be continued...]

Building Roody's Lugged Road Bike: Part 1

Roody's planning a tour up the East Coast

   and he needs a reliable bike: to pull his trailer with, and that fits him comfortably enough to ride over a thousand miles in a month. So, we're building it.
   The kit I'm using is essentially a spare kit that a friend had boxed up the basement for a couple years and never got around to building. It's a lugged, straight gauge road kit for a 6 foot tall male. Perfect for Roody, who is a little shorter, but feels more comfortable on a taller frame. It'll be a little heavy, but tuff enough to weather the long trip, and a few more.

   Since I had to design a bike that worked with the kit, I laid out a rough drawing of the bike we were aiming for. Easy enough, we had previously taken his measurements and discussed what he was looking for in this new bike.

   Once I had a general idea of the sizing, I proceeded in cleaning the front triangle tubes and lugs thoroughly with sandpaper and a wire brush, and rough fit them together. Then scribed the tubes and mitered them with hole saws on the drill press. Easy does it.
 
    I didn't have the specs for the seat & head tube angles so there was a lot of guessing, trial, and error involved. After a few extra cuts and a little filing, it all came together. After cutting the breather holes and aligning on the bench, its ready to be brazed together!

[stay tuned...] 


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