First off, I have no idea what a colored animal has to do with Build a reproduction frame but let me proceed. I accepted a commission to build a repop of a frame I built a long time ago. I made good progress at the beginning then got stalled for a while. I couldn’t find a tube I needed. Specifically a 25mm track fork leg in an extra long length.

The original part was made from a Tange “D” profile unicrown road fork leg. Who would have thought they would no longer be available? So the next thing to do would be to figure out how Tange made the leg. I deduced it was originally a 25mm tube (not 25.4/1″) and it was pressed into the D shape in a 1-1/8″ 1/2 round die. Don’t ask me how I know.

Anyway I couldn’t find a part long enough although I wasn’t sure how long it needed to be exactly. The reason I knew this is because I made a sample and dented it all up and it was one of the last two of the longer type. In other words, I had one tube and needed two.

I found another 25mm track leg and only needed to make it 50mm longer. I was worried that with all the heavy tube forming that I would have some kind of issue. I made a short piece of tube in the lathe and spliced it on to the shorter fork leg. I then remembered this whole blog thing and took a photo.

At this point, we now have two of the same tube to make two D shaped chainstays with tight bends. You can see the sample above the other two.

The next thing was to sift some sand. We are going to be packing this sand into the fork legs to help us bend them. Wait! first we need to make them D shaped.

I used the tube clamp block and flat par see in the above image and did this.

THEN I sifted the sand

then I dried the sand

Then I filled the tubes and capped the ends

Next, I rigged up a tool to make sure I had the same bend radi and length-to-end.

Flux’it and get it red hot and lean on it hard. It’s good then.

Check the angle in your angle checker.

Finished bends

OK, That’s it for now. I need some cereal.