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Built this wooden jig to support them while welding. Sent from my iPad using Tapatalk

Working on a set of bars today. Not as much fun as I expected. Sent from my iPad using Tapatalk

Thank you! It was a lot of work but there are not too many other options. Sent from my iPad using Tapatalk

Welded up and most of the grinding and shaping done. Just resting on blocks of wood right now, i need to relace the rear wheel and get rid of the Pugsley offset before i go any farther. The radius isn’t perfect so ill have some tweaking to do before final mounting . Sent from my iPad...

Here it is after some chopping and sectioning! Sent from my iPad using Tapatalk

Finding a fender for this beast has not been easy, I’ve seen lots of motorcycle fenders that had the look i want but not the radius or the price tag I’m after. Bicycle fenders aren’t strong enough to use as my seat support. With no real sheet metal tools, making one wasn’t really an option. Ive...

I looked at the foam that I cut out for the seat and I was thinking it looked like a coffin tank. Thanks, with the green cover on it looks a lot like a banana seat, almost too much like one so I’m making a few minor changes. Sent from my iPad using Tapatalk

Thanks! I’m curious also, I have a basic plan but things change every time I work on it. Sent from my iPad using Tapatalk

Finished welding the frame today. Mounts for the seat pan and the elusive bottom bracket shell are done as well. Now time for some sort of rear fender to support rear of seat. Sent from my iPad using Tapatalk

I didn’t post pics of the construction of the pad because I’m not happy with the results! Its going to get a redo so I will definitely document my process and share it. Sent from my iPad using Tapatalk

Seat building progress Sent from my iPad using Tapatalk

Yes the main tube is 4” x 4” x 8’ long. Very hard to take a complete picture in my cramped and small shop. I choose my wheelbase measurement and weld the sign posts in position and build from there. I use pieces of allthread as dummy axles to set hub spacing and center bike to tube. Sometimes I...

Started working on a seat pan today. I’m using a scrap piece of aluminum that used to be the top deck on my xtracycle. Made a pattern, cut it out, then threw it on my fancy sheet metal bender. I’d like to get the seat built, upholstered and mounted before continuing on with bottom bracket...

Thanks everyone! I need to build a seat for it before I weld in the bottom bracket. I want to make sure I have my seating position dialed in before committing to bb placement. It’s going on top of the gusset not in the hole. Bottom bracket height is good, I should have about 3” clearance...

Welded up the rear enough to throw the wheels on it! Sent from my iPad using Tapatalk

I was gonna go that route, but I have another possible solution in the works. Im working on making the rear triangle bolt on and have some side to side adjustment. I think i can shift it over to use the Pugsley wheel. If I like how it rides i may get proper wheel built and shift the rear back to...

Mostly finished with the front half of the frame. Working on rear stays and dropouts next. The rear rim is laced offset 17.5 mm and I don”t want to relace it in case i need it back on the Pugsley so I’m gonna have to get creative! Sent from my iPad using Tapatalk

Yesterday was day one for me. Made a bit of progress on front triangle. Sent from my iPad using Tapatalk

I’ve got a set of 29” x 3” wheels in the shop that sometimes are on my surly Pugsley. I’ve been wanting to build a custom frame around them for a while and now seems like a good time. First step for me was buy a triple tree fork off eBay so I couldn’t turn back. Fork will most likely be...

Thanks! This thing has some sort of serial # buried in paint but no other identifying marks other than the original decals. It's pretty heavy and seems well built. Sent from my iPad using Tapatalk