Mechanique
1 sub-album and 78 images in this album on 5 pages.
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Silver brazing the brass preform coil at the head lug end of top tube.  This ensures the coil stays in position as the frame is rotated in the Marchetti frame fixture.
Silver brazing the brass preform coil at the head lug end of top tube. This ensures the coil stays in position as the frame is rotated in the Marchetti frame fixture.
Viewed: 328 times.
Same shot but of the seat lug end of the top tube.  The down tube will get the same treatment at the head tube end of the down tube.
Same shot but of the seat lug end of the top tube. The down tube will get the same treatment at the head tube end of the down tube.
Viewed: 332 times.
Custom cut lugs.  Long Shen precision cast steel oversize lugs which have been modified with an end mill, slitting saw, drill bit, and elbow grease.
Custom cut lugs. Long Shen precision cast steel oversize lugs which have been modified with an end mill, slitting saw, drill bit, and elbow grease.
Viewed: 365 times.
Lug tacking.  When you need a Third Hand, the old Var Third Hand comes in "handy".
Lug tacking. When you need a Third Hand, the old Var Third Hand comes in "handy".
Viewed: 348 times.
Head tube end mitres on the top and down tubes are now complete and the tubes are returned to the frame fixture to check alignment.  Mitres are light tight and good to go.
Head tube end mitres on the top and down tubes are now complete and the tubes are returned to the frame fixture to check alignment. Mitres are light tight and good to go.
Viewed: 321 times.
Down tube stainless steel gear cable guide brazing fixture.  A Palmgren vise out of the '70's holds the pin which applies a small load to the guide during brazing.  The bottom bracket shell end is picked up by a calibrated turntable allowing the tube to be accurately rotated for the second brazing operation.
Down tube stainless steel gear cable guide brazing fixture. A Palmgren vise out of the '70's holds the pin which applies a small load to the guide during brazing. The bottom bracket shell end is picked up by a calibrated turntable allowing the tube to be accurately rotated for the second brazing operation.
Viewed: 333 times.
Detail of cable guide and hold down pin after silver brazing.
Detail of cable guide and hold down pin after silver brazing.
Viewed: 337 times.
A head tube extension has been fabricated out of the bottom rim from a down tube lug and brazed to the top end of the head tube.  The head tube with both top and bottom lugs tacked is now ready to complete the main triangle for brazing.
A head tube extension has been fabricated out of the bottom rim from a down tube lug and brazed to the top end of the head tube. The head tube with both top and bottom lugs tacked is now ready to complete the main triangle for brazing.
Viewed: 317 times.
The frame is fitted up on the Marchetti frame fixture for the final check before brazing tomorrow.
The frame is fitted up on the Marchetti frame fixture for the final check before brazing tomorrow.
Viewed: 320 times.
The main diamond of this frame is brass brazed and ready to take a nice soak in the hot tank.  Sandblasting, lug filing and the wishbone rear triangle still to go but not too many more days to go to paint.
The main diamond of this frame is brass brazed and ready to take a nice soak in the hot tank. Sandblasting, lug filing and the wishbone rear triangle still to go but not too many more days to go to paint.
Viewed: 314 times.
The seat lug must be slit before the wishbone topstay binder is brazed to the frame and this is the simple set up on the Bridgeport mill.  The frame is held in an old Var tube clamp which is clamped in a Kurt milling machine vise.  A 0.128 inch slitting saw is used to perform the operation.
The seat lug must be slit before the wishbone topstay binder is brazed to the frame and this is the simple set up on the Bridgeport mill. The frame is held in an old Var tube clamp which is clamped in a Kurt milling machine vise. A 0.128 inch slitting saw is used to perform the operation.
Viewed: 293 times.
Detail of seat lug slitting.
Detail of seat lug slitting.
Viewed: 302 times.
Lug work.  After 45 years I've found a little wine after 6pm helps the effort.  Still a bit of a slog.
Lug work. After 45 years I've found a little wine after 6pm helps the effort. Still a bit of a slog.
Viewed: 313 times.
Detail pic.  Macro seems to be best.  By the way, lug work is far from finished but coming around.
Detail pic. Macro seems to be best. By the way, lug work is far from finished but coming around.
Viewed: 344 times.
The wishbone topstay binder was previously brass brazed using a preform ring placed inside the 19mm topstay tube.  This photo shows the silver brazing of the topstay binder to the rear of the seat lug.  The binder itself is milled from a piece of 4130 round stock and mitred with a 31mm mitre cutter to match the diameter of the seat lug at the angle of the seat tube/topstay joint.
The wishbone topstay binder was previously brass brazed using a preform ring placed inside the 19mm topstay tube. This photo shows the silver brazing of the topstay binder to the rear of the seat lug. The binder itself is milled from a piece of 4130 round stock and mitred with a 31mm mitre cutter to match the diameter of the seat lug at the angle of the seat tube/topstay joint.
Viewed: 299 times.
Fixturing of the wishbone rear triangle on the Marchetti ML 301/G-500 frame jig.
Fixturing of the wishbone rear triangle on the Marchetti ML 301/G-500 frame jig.
Viewed: 325 times.
Another photo of the wishbone rear triangle showing the alignment clamp and the dropout clamps.  Once the topstay binder is silver brazed to the rear of the seat lug the seatstay tips are brass brazed into the Llewellyn cast dropouts.
Another photo of the wishbone rear triangle showing the alignment clamp and the dropout clamps. Once the topstay binder is silver brazed to the rear of the seat lug the seatstay tips are brass brazed into the Llewellyn cast dropouts.
Viewed: 333 times.
Seat cluster detail.  10mm button head stainless steel bolt completes the binder.
Seat cluster detail. 10mm button head stainless steel bolt completes the binder.
Viewed: 320 times.
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