Lumpy/beaded fillets

[ohio]

I’m curious both how to create beaded fillets like those done by Drust (https://www.instagram.com/p/ClmaU8PM...d=MDM4ZDc5MmU= ) and Cattin (https://www.instagram.com/p/Cmgip9js...d=MDM4ZDc5MmU= ), and also if there are any issues with strength or longevity that result from the technique. I find the results quite beautiful, and it looks incredibly challenging to create such fillets. Thoughts or experience with this?

[steve garro]

Run cold & don't fully pre-heat your parent metal to avoid having good wet-out on the edges.
Basically, the opposite of what you want if you are going to file it down

- Garro.

[corey thompson]

This has been a popular method on motorcycle frames for a long time. Here's a youtube video that does a really good job of showing it.

-Corey Thompson

[claritycycler]

^
Very nice vid of the method, inline fluxer makes it easier to see. Seems like if the joints are heated/penetrated adequately with the filler the fillet wouldn't need to be that large(except for cosmetics), could the brazed "beads" be about half that size and be strong just as strong? IIRC there is some formula for the minimum fillet radius and gap size of the joined tubes.

[steve garro]

^
IIRC there is some formula for the minimum fillet radius and gap size of the joined tubes.

3x wall thickness at the root + internal penetration of filler

- Garro.

[progetto]

^
Very nice vid of the method, inline fluxer makes it easier to see. Seems like if the joints are heated/penetrated adequately with the filler the fillet wouldn't need to be that large(except for cosmetics), could the brazed "beads" be about half that size and be strong just as strong? IIRC there is some formula for the minimum fillet radius and gap size of the joined tubes.

https://www.flickr.com/photos/arregu...wWgoJYs6nJnj88 check out this guy, he believes so, I'm in the Garro camp, large hot fast fillet with a nicely wet edge, can't go wrong.

[steve garro]

metalwork 2008 713_rs.jpg8F03470C-E2AD-4E92-AAFE-D69C0F5B4784.jpeg

https://www.flickr.com/photos/arregu...wWgoJYs6nJnj88 check out this guy, he believes so, I'm in the Garro camp, large hot fast fillet with a nicely wet edge, can't go wrong.

Small ones are fine until they aren't, usually an impact, but, you want the tube to buckle, not the fillet to fail.
Also, polishing small fillets SUCKS.
I call it "working in the ditch."
This is why the old school guys who made 1000's of fillet frames production style laid such huge ones, they are able to be cleaned up almost completely with a dyna-file working "outside the ditch"
A big moment for me was seeing Steve Rex's work where it looked like the brass was applied with a trowel and he said "Three frames polished before lunch."
Holy Hell

Here is some of mine for a long time ago (totally unfinished) and some new ones



- Garro.

[ohio]

Very cool, thanks for the follow up and info, folks. Thanks to the tip on motorcycle frame fab, found this guy who is building what I think is the most stunning frame on the motoGP circuit: https://instagram.com/kam_fab?igshid=MDM4ZDc5MmU=
Mind blowing that such an old technique and material can be competitive at the bleeding edge of racing…