Tuesday, January 27, 2009

day five.

here i am building a mounting jig to locate the pangea speed axle plates on my table. i have measured out the axle height on the centerline of the axle and the center of the slot. i also spaced the plates to accept the hub with out needing to machine new spacers. i tacked the entire jig before welding anything fully to reduce warpage of the jig.

this is what the jig looks like when its fastened to the table. i marked the centerling of the jig and measured 100 times to make sure its was square.

grind off all the extra metal from where the previous frame points had connected. i used a big 3in grinder to knock them down then 24g, 50g, scotch brite roloc discs and a single cut file tofinish the areas.

this is just a basic tube bender that can be purchased at harbor freight. i measured the bend angles with an angle finder then bent the tubes as close as possible to where i needed them to be.

figure out your seat stay width based on your measurment you used for your axle plate location. (make sure your chain and sprocket are going to clear the seat stay)

figuring out how to cutout the slot for the axle plate was a bit of a trick. what i did was clamp the bent portion of the tube in a vice with 2x4's the 2x4's allow the tube to sit in the vice square. once you have the tube squared up you and use a block on the side of the tube to measure off to determine the centerline of the tube. this all might sound like a big hassle but it really helps you get the relationship between the axle plate slot and the bend clocked in the propper relationship.

here are the seat stays resting roughly in there new place called home. always make sure to test fit stuff you can really avoid some head aches that way.

another test fit with the slots and tube caps welded on, for the tube caps i just used some 1/8 in strap, cut it with a band saw, weld, and grind her smooth

another view of the tube end test fit.

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