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  1. tjwilson

    Tweaker's Rehab

    Seat Base Front Mount Started by trimming up the main curved tubes and then making a paper template. I know that this attachment needs to be pretty solid so I made sure to give myself enough room to get a socket onto the bolt/nut.
  2. tjwilson

    Tweaker's Rehab

    Sissy Bar / Seat Support Started this out by bending 1/2" tubing to try and closely match the solid bar template I had been using for mock-up. Top loop from three sleeved pieces of tubing. The bottom ends of the side pieces were coped and short sections of tubing were cut for attaching the...
  3. tjwilson

    Tweaker's Rehab

    Finalizing the Seat Base The tubing that makes up the perimeter of the seat base was just loosely taped together. I made a paper template, tracing one side, folding it in half, and mirroring the traced side. I then transferred that template to 20ga sheet metal, trimmed and bent that to match...
  4. tjwilson

    Tweaker's Rehab

    "This Indecision Bugging Me..." "...Esta indecisión me molesta". I've been struggling with the design of this and feel like I've been stuck in a Clash song on infinite repeat. The first pass (and multiple variations) just weren't cutting it. I think I've at least determined that the whole...
  5. tjwilson

    Tweaker's Rehab

    Seat Base Loop In the past I've always had tubing deform too much at the point where the die presses against the tube in a pipe bender. This time around I tried stepping down in die size gradually after filling the tube with sand. Didn't create a smooth circular bend but I liked the curve that...
  6. tjwilson

    Tweaker's Rehab

    Seat Base - Fender - Sissy Bar Started out with some half inch tubing to create a seat support. A bottom pan and fender skirts will eventually by welded to the tubing. Pieces trimmed from the main curves. Sleeved and positioned.
  7. tjwilson

    Tweaker's Rehab

    Thanks. I can remember fifteen years or so ago seems you could find that kind of gear at the curb every garbage day. Me and that specific derailleur have a history. It first served duty on the overweight contraption below. Man, I have cut up and repurposed parts from some really nice bikes in...
  8. tjwilson

    Tweaker's Rehab

    Rear Hub Still haven't had time to order a new rear rim or figure out spoke lengths yet but, I do have a hub in hand. For simplicity in figuring out the braking I went with a Sturmey Archer drum brake / freewheel hub.
  9. tjwilson

    Tweaker's Rehab

    Bottom Stays More modifications to the rear triangle. I had a five speed derailleur on Tweaker that cleared these but, with the angle change (and a slightly wider hub) I wanted to make sure I had room. The new stay legs come courtesy of some old handlebars.
  10. tjwilson

    Tweaker's Rehab

    Bottom Main Center and Downtube Connection Before getting into the bottom stays I cleaned up and welded the rear bottom frame connection.
  11. tjwilson

    Tweaker's Rehab

    Top Stays Backing up a little... before I did the final welds on the dropouts I cut the top stays to final length and rounded the front ends.
  12. tjwilson

    Tweaker's Rehab

    Non-Drive Side Extension When I welded the one side of the non-drive extension on I must have accidentally hit the settings, or something. Not really sure. In grinding down the inside weld there were voids where the two pieces met. I ended up using a cutting wheel to cut into the weld...
  13. tjwilson

    Tweaker's Rehab

    Rear Dropout Extensions I've moved the rear triangle from Tweaker forward and changed the original angle. Made a template to extend the dropouts, cut them from 3/16" sheet metal, welded them on and ground the welds smooth.
  14. tjwilson

    How to bend Sissy Bars?

    Hey that's my bike! Pretty cool to see someone wanting to do a sissy bar somewhat similar. Yeah function.... pfffft ;). Actually putting that curve in there had me sweating a bit. I monitored the dimensions for a good six months, totally expected to have to redo them but they've held up to...
  15. tjwilson

    Tweaker's Rehab

    Tacking up the Frame Center Section This is the second build that I've used this fixture on. Awesome tool, a laser helps too. The main backbone tube on this build has a very hard to find center. Image on the left shows the misalignment of the initial tack that I had of the head tube/backbone...
  16. tjwilson

    Tweaker's Rehab

    Trimming and Notching the Backbone and Down-tube
  17. tjwilson

    Tweaker's Rehab

    Building on Character - Revised Down-tube (2) Sleeving the down-tube pieces. Fixtured, welded and smoothed-ish. Ended up close to the solid rod template.
  18. tjwilson

    Tweaker's Rehab

    Building on Character - Revised Down-tube I didn't care for the shape of the existing down-tube and wanted to re-bend it. A while ago I built a few stands to hold wheels and a dummy crank. Built a head tube stand too but didn't use it this time around. Anyway, the idea was to change my...
  19. tjwilson

    Riff Ratt

    That is a classy looking ride! Sounds like you’ve got the bending issue fix. I’m thinking the chain skip might be corrected by increasing how much the chain wraps around the rear sprocket? Moving the tensioner forward and/or changing the angle should take care of that.
  20. tjwilson

    Huff the mighty…..

    Cantilever delete / straight bar add looks great. Rounding the ends of the cutoff cantilever/seat stays look clean. Nice detail.
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