Monday, December 29, 2014


I've been working on ways to make the frames faster and more consistent.  In particular I've been working on the joint process.

Below is the new release layer being removed from the test joint prior to laying the carbon fiber.

After a standard bagging and baking process this is the result "out of the oven".  It took only seconds to unwrap the test joint.  Previously, using release cloth, this was a time consuming process.

Below on the left is the bare sanded tube I used for the test joint.  On the right there are 5 layers of uni-directional carbon.  It almost looks transparent in the photo but it's actually the texture of the tube itself duplicated in the new release layer process.

On one half of the joint I experimented with allowing resin overflow through small holes in the release layer.  Not sure it was worth the extra effort, not much resin flowed out into the breather layer.  I's also difficult to remove the little epoxy nubs cleanly.

Up next should be a new road frame using this process for the tube joining.

Sunday, May 04, 2014

Cross Assembled and Tested

The larger of the two frames was for me.  I've put over 900km on the bike now, some of which was on very rough gravel Jeep roads.

Here it is assembled waiting for it's first ride (and for the snow to finally melt).
 Some of the detail in the seat cluster area.
The TRP front brake and re-painted ENVE fork.
This is how the heavily modified Crumpton dropouts and shortened ENVE seat stay molding turned out.  Note the stay cable guide.  I used solid casing from bar to derailleurs on this bike to keep everything running smoothly.
In April I was riding in South Carolina and finally, having the right bike along, did a loop using Horsepasture Road.  It's a Jeep road located in the Jocassee Gorges Management Area.  Horespasture Info

After riding the loop I'd suggest a 29r over a cross bike.  34x28 low gear and 33C tires were not ideal for riding this loop given the steeper pitches, loose surface in places and my poor spring climbing form.
The view from Jumping Off Rock lookout was more then worth the climb though.
If nothing cracked or broke on the frame on the bone shaking descent I can't see it being an issue where I normally ride.

Finished Cross Frames

It's been a while since I last updated.  I've since managed to have both frames painted and one assembled and test ridden extensively.

Here is the smaller frame back from paint.  It had matte clear logo under gloss finish applied.

Here is the BB area.

And one of the hand made cable guides (titanium tubing wrapped in carbon).
More photos to follow once this frame is built up.