Zombie Resurrection - speedbuild - slowed back to normal speed..

[SkyknightJohn]

So, in the 2022 Summer buildoff I made “A Zombie Reborn”
A good looking bike, not terrible to ride, but compromises were made and I know where (but I’m not telling).
Overall I’ve never been fully satisfied.

This is the Resurrection.

A totally new scratch build in the same spirit and geometry, but better, I hope.

I have five days to build a frame.

Day 1:
Full scale drawing while waiting on contractors (who never showed ).

Day 2:
… while herding contractors who needed adult supervision…
Finished the seat insert to insertable size. Since I don’t have a mill or lathe, that meant a lot of filing and grinding by hand.
—->(Paragon Machine Works 1-1/4” OD “any size” seat tube insert. Relieved ID for 27.2 seat post, finish the insert to your needs.) Allows for thicker wall welding at the TT-ST-SS junction while keeping a thinner wall elsewhere.

I should mention all front triangle tubes are 1-1/4” x 0.035” straight gauge.

Bloody Red dropouts cut from the Reborn Zombie.

And the bottom tube cut/mitered, down tube cut for the junction. Miter @ HT tomorrow.

Can I complete the frame in 5 days?
Challenge accepted!
Will my wife find out I’m using the dining room table for layout?
Not if I finish in five days!

Stay tuned! or tune out, It’s your holiday.

 

[SkyknightJohn]

Day 3:
Only two pics but they represent a lot of work. Main “triangle” coped and fitted. Yes, that bottom junction will get some reinforcement.

Funny how the computer drawing and the real thing come out looking different. I just need to get a bender for thin wall tubing so I can add real style.

Chain Stays also mitered and ready.

Tomorrow is tack and weld day.
I’m excited. Are you excited? Leave your comments below, and Remember to like and subscribe, ring that bell to get notifi…..
Oh, wrong platform… carry on.

 

[Captain Awesome]

Do you have a purge coupler for your HT and BB? Couldn’t remember

 

[SkyknightJohn]

For the BB, yes, but not the HT. I’ve not found any off the shelf options that were’t part of an entire jig. Many builders make their own.

I’ve never actually backpurged, though, only using the heatsink portion of the BB bit to avoid distortion. There are differeing opinions on whether steel really needs backpurged, with equal numbers of builders reporting ‘yes they do’ and ‘never have.’

 

[MattiThundrrr]

Remember to like and subscribe, ring that bell to get notifi…

Already liked and subbed, didn't turn on notifications cuz I'll be checking in regularly. I love that little corner in the down tube, got some nice angular style going down there

 

[Captain Awesome]

For the BB, yes, but not the HT. I’ve not found any off the shelf options that were’t part of an entire jig. Many builders make their own.

I’ve never actually backpurged, though, only using the heatsink portion of the BB bit to avoid distortion. There are differeing opinions on whether steel really needs backpurged, with equal numbers of builders reporting ‘yes they do’ and ‘never have.’

Agreed. Depends on the steel and whether you’re going to heat treat or not but I’m in the largely unnecessary camp

 

[SkyknightJohn]

Day 4: Running behind….
More contractor wrangling today, oh, and a gas leak. “please don’t smoke or strike a spark, ya know, like arc welding or anything.”

All fixed and safe.

I welded the BB-CS-Dropouts today. A bit different order, where normally the front triangle is done first, but I’ve seen some builders go this way since that tricky spot on the BB between the CS’s is easier without all the rest built up.

Here it is mounted on the jig:

Been practicin my welding just a bit:

Not perfect but I think It’ll do, pig. It’ll do.

Managed a bit more jigging up before calling it a day. Tomorrow, the Saturday before Christmas, should have no interruptions… wish me luck!

 

[SkyknightJohn]

Day 5:
Didn’t quite get ‘er done. Still need to add the Seat Stays, downtube reinforcement, and bits and bobs. Front frame and chain stays fully welded up. Most of the welds came out well. Some are a little goobered, but oh well.

 

[SkyknightJohn]

Day 6:
A little time to work today. The best frame maker’s tool right here:

With a gratuitious foot shot, for those who care!

Worked with string and the Sheldon Brown 2x4 alignment tool. Still a ways to go. Seems my rear end jig & weld first method was worse. Not just left-right-center, but a twist. Maybe I’ll get it, maybe it was a good practice session, with lessons learned and a donation to the scape tube practice pile.

Either way…

 

[SkyknightJohn]

Seems a day away and clamping the frame in the vise did the trick. Alignment looks good. Next: seat stays.

 

[SkyknightJohn]

Back to a slow pace… seat stays on.

nest will be downtube junction reinforcement, CS SS braces, then make it roll to check If it’s good enough to continue through to buildout & paint.

 

[BartRidesEternal]

Back to a slow pace… seat stays on.

View attachment 255297

nest will be downtube junction reinforcement, CS SS braces, then make it roll to check If it’s good enough to continue through to buildout & paint.

Looking good! Love your frame building skills.
Interesting frame design. At the angled tubes right before the bottom bracket, you could assemble a guard of sorts:

 

[SkyknightJohn]

Interesting idea. I’ll give it some consideration.
Moving really slowly here as my schedule’s been packed and this winter storm messed with everything.
Oh, and I’m doing the SWBO too!

 

[SkyknightJohn]

Officially, I'm putting the kabosch on this one. It was a good, fun thing to do to kill time and practice while the other half was away just before the holidays, but, after taking the frame class in Jan-Feb, and considering what I learned, the issues I had with this frame, some inside knowledge of the welding, etc...

It is donating the usable parts and tubes to the next project and practice pieces.

I like the design/layout, and will be exploring options for a good cruiser -with style- for a summer build. But for now, adios amigos, ce fin, ciao!