"Building a welding JIG first" - design process and thoughts

[BartRidesEternal]

Electra Ratrod jig tryout: HERE WE GOOO!

The jig is very sturdy!

I will lengthen the bike about 18 centimetres.

Positioning the jig is still temporary. I plan to hang it on a tilting frame on the wall or hang it on the ceiling of the shed, so I can work around it.

 

[BartRidesEternal]

I ordered tubing for the 'lengthening' of the Electra Ratrod bike.

@Captain Awesome should I create another topic for the build of the Electra bike? Or just document it here, since it is a learning project?

I also made drawings for the rollers.
Since manufacturers have pricing for 'roller sets' I thought I am being smart by combining two smaller tube diameters it also helps with changing: I have to change less times for alternating tube diameters.

The tubes have an offset: I learned that by looking at the original rollers. This way the tubes will not get stuck in the rollers. But the rollers do not give the tubing space to bend in undesireable ways....

Material of choice: Toolsteel.

 

[Captain Awesome]

I ordered tubing for the 'lengthening' of the Electra Ratrod bike.

@Captain Awesome should I create another topic for the build of the Electra bike? Or just document it here, since it is a learning project?

I also made drawings for the rollers.
Since manufacturers have pricing for 'roller sets' I thought I am being smart by combining two smaller tube diameters it also helps with changing: I have to change less times for alternating tube diameters.

View attachment 278301
View attachment 278302
The tubes have an offset: I learned that by looking at the original rollers. This way the tubes will not get stuck in the rollers. But the rollers do not give the tubing space to bend in undesireable ways....

Material of choice: Toolsteel.

Your choice

I’m following along either way

 

[BartRidesEternal]

Tubing came in!

26mm for inner sleeves.
38mm for the chainstay part. I am pressing the 38mm a bit oval, like the original tube.
30x2mm for the top tubes. I will put these in the lathe so I can match it with 29mm original diameter.

Perfectly tight. Light taps with the hammer.

All sleeves are in perfectly.

Next step will be tube alignment since the chainstay/lower tube has a slight different angle.

Exciting!

 

[BartRidesEternal]

I put the 30mm tubes in the lathe and made them 29mm like the Electra frame. Wall thickness is now 1.5mm, also like the original.

Back home, I cut the tubes to size and checked the sleeves. They fit perfectly!
Incredibly satisfying

38mm lower (chainstay) tube in the hydraulica press. To match it with the original from the Electra frame.

Little dents on the top and lower part. Not a big issue, gotta keep it to a minimum.

Done!

Does the straight piece of the top tube interfere with the Electra lines? What do you think?

Little gap to be filled. Brazing has a capillary effect, so it will be tough with the sleeve inside.

Le perfect!