Llewellyn Bikes

[Rody]

Dazza,

Nice to see you back

rody

[Too Tall]

Well done boy :) Really nice to have you back.

[Dazza]

The top head lug is next to get some attention.



I copy the bottom head lug profile and then transfer to the top head lug and then alter to fit the different flow and angle of the top tube









Before and after sugery

[Dazza]

Seat lug time








the lugs are done





The Nigella Curves

[savine]

Nigella as in Lawson? Nice to see you back, always amazed by your work.

[progetto]

Is there any other Nigella?

Nigella as in Lawson? .

[Dazza]

What's he building in there?
What's he building in there?

We have a right to know...










And what's that tune he's
Always whistling...

[dashDustin]

Wait...that was 4wks from hello to completion? As in 28 days?

[Mark Kelly]

Dazza

Great to see you back. Quick question about the tails on the asymmetrical heart: the ends are tweaked with pliers? I can't see how you can obtain the length otherwise.

Not trying to steal ideas, just curious. I don't have the patience to carve lugs or polish stainless.

[Dazza]

Wait...that was 4wks from hello to completion? As in 28 days?

Yes. Stainless fork crown, Fenders are fitted to the frame with stainless studs, then there is making the racks, 316 stainless tube, fitting the bag's attachments (not with dreadful straps), assembly and clean up of workshop. Stay tuned to follow why.

[Dazza]

Dazza

Great to see you back. Quick question about the tails on the asymmetrical heart: the ends are tweaked with pliers? I can't see how you can obtain the length otherwise.

Not trying to steal ideas, just curious. I don't have the patience to carve lugs or polish stainless.

Yes, I have a set of Pliers that were Dad's, and I have ground the ends to assist this, I tweak and then smooth with the abrasive drums/die grinder.

[Dazza]

Each tube is inspected and butts marked. If one is doing a good job you will ensure the butts are used correctly, so most times the both ends of the tube is trimmed/mitred



Stainless steel Schmidt front drops as they come out of the box



I mill a small slot for the cable tube to nestle into. One of those details that make the bike build 4 straight solid and very full weeks, excluding other time interruptions!



Tight is nice







Filler material and silver braze



I anneal the brass tube before it is used
Cook up

[Dazza]

Finish work on the front drops begins







Stainless steel facets are brazed to the drops using silver. Note: no remelt of the previous braze



the braze fingers etc are machined from Titanium (tip # 5629, send your payments to ............)



My days are long and the day is late when I set the Marchetti up for this frame



Time for dinner

[Dazza]

The fork is brazed with a stainless steel fork crown.
Single point turning of the fork to machine the crown race seat in the lathe
Superior result compared to a hand reamer, especially with stainless steel.



A bit of time to get a good following line around the wheel. You do this before paint is done, saves a lot of grief with marked paint. All adds to the 4 weeks eh!



Finishing the cut Honjo stay, balsa and 1500 grit
Makes all look neat and proffie





I replace the screw with a nicer one when I assemble the painted bike.

[Dazza]

I do the M6 stud and Nyloc nut Those under crown draw bolts are a pain if you want to remove your rack, you have to loosen the mudguard off (that's a fender for those in the USA)
All is stainless steel. No rusty rusty here.



before and after shots of the drops



Saw and file and sand to 1500 grit and polish. Details to make the 4 weeks fill up



Stainless steel facets ensure the paint is kept tidy when the wheel goes in and out. It is the second decade of the 21 st Century, I reckon we need to have our stuff rise above the ..........

[bryand]

I just wanted to post a sincere thank you for sharing your process and getting back into the forum. I appreciate the attention to detail and the time it takes. Cheers.

[Dazza]

I just wanted to post a sincere thank you for sharing your process and getting back into the forum. I appreciate the attention to detail and the time it takes. Cheers.

Thank you. My pleasure.
Bryan, are you the same chap who worked a bit with the Aussie team at Tour du Pont circa 1996?

Cheers

[Dazza]

forming up the main frame
TT to HT




cut out the DT, old boss showed me this, a detail I have to do on all Llewellyns.



DT to HT. These are machine mitered

[Dazza]

A bit of fork work



Ginger's dad is a retired Journeyman Machinist who made the robots that manufactured engine blocks in Detroit.
He gave me a half dozen Starrett sliding parallels of different sizes. These are just so incredibly useful, I wondered where they have been all my life
I use one to align the fork under the mill/drill.



Back to the main frame, fit up of the lugs, grinding internally to ensure there is no stress in the set up.



The rear drops are my investment cast stainless steel ones. The front drop are the special Schimdt ones fro the connector less Son Delux generator hub.
These drops are external sockets, to match a lugged frame. They work super well.



I rework the socket shape to make to give them a touch more elegance



Grind grind, whizzzzzzzzzzzzzzzzzzzzz goes the die grinder



Cook up



done

[Dazza]

Drop out filing, sanding and primary polish.



This takes some hours to do.
Sanding in steps to 1500 grit
The axle entry has beveled edges to ease entry of the wheel. Once upon a time if a builder did not do this they were frowned upon with contempt..



the buffing polish takes only minutes, it is the surface prep that is the toil. Best done listening to Test Cricket on the radio, or the current World Cup



The one M5 eyelet is for the mudguard (fender) , the other has been removed



I only give them a 80 to 90% polish as after all is done the full polish is done after all brazing, pickling and finish work is done