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"Any whole hole with a hole bitten in it, Is a holey whole hole And it JUST - PLAIN - ISN’T!" -- Homer Price

Never underestimate the power of cardboard! Personally, I found one of these PVC flanges laying by the side of the road. I use it like a pedestal to keep the scratchy bits of a hub off the floor or tabletop.

What he said ↑↑↑↑ Nice example of a ladies version, tho. Might be one of the only ones in AU.

The only thing I can think of that MIGHT come close to fitting would be a BMX cam brake, like the old Odyssey Pitbull. Those brakes do not come cheap!

Yes...ISO/ERTRO = 630

So...you gonna change your handle to Grampy Shish?

From a purely mercenary point-of-view, Abner serves as a showcase for your new tank. Do you really want to distract from that focus by adding the rack? The final decision might depend on the saddle you choose--it certainly did on Speedline BRAT.

That heatsink idea is beyond clever! I was thinking something along the lines of a ribbed rubber floor mat, which would be a lot easier to source and work with...not to mention cheap. I have one here I keep my wet shoes on that, apart from being black, looks just like those fins.

Those break-away pins are slightly tapered on the discarded end, making them much easier to insert and align. Discrete pins are necessary on a chain made of half-links because a typical master link can't be used.

Proportions look good. Anxious to see it with the loaf pans and pipes affixed. The exposed part of the headtube reminds one of a Vertex magneto.

I expect that would be very difficult to achieve with basic hand tools. Some bike shops have a frame straightener with an adjustable fulcrum. That might kinda work.

Congrats...but I can't hide my astonishment!

The cushion can hide a lot of ills. Looks like the nose took a beating, though, and could use a little massage.

I'm definitely down to learn more! I've got one of the 'legacy' machines--an Expression--that I've hacked to use Sure Cuts a Lot and other software, rather than the proprietary cartridges. I also dabble in Inkscape, to create and modify the vector files that you're talking about. Have you...

A lot of non-profit co-ops are plagued the same way...ours included.

Maybe check with these guys? If they can't supply you with the proper seatpost, they can likely measure it accurately, at least. http://worcesterearnabike.org/

Seatposts are sized by their diameter in mm and their length--there are many sizes. Some are quite common; others are oddball. If you're lucky enough to still have the original post, the size is typically engraved or laser-etched somewhere near the markings for minimum insertion...

To my eye, sans louver is more appealing. That could be a trick of light and color, though--the original 'louvers' are just painted on, correct?

Ah yes...speed rail. Like Lebowski's rug, it really ties the room together.

This actually begs a question: Could a skip-tooth chain be 'revitalized' by replacing worn pins and rollers with parts cannibalized from a modern 1/8" chain? Has anyone even tried?