28-JAN-2013
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Seat Lug ready for finishing.
28-JAN-2013
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View of bottom bracket lug showing some filled epoxy added to fill in some voids.
28-JAN-2013
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Head tube lub ready for finishing.
28-JAN-2013
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Day 6 & 7: Finishing of Lugs & Bamboo Surfaces
First a thin layer of slow-set epoxy was brushed on all carbon areas to create a smooth, hard surface. After thorough curing overnight, surface was lightly scuff sanded to remove any stiple bumps, then a coat of polyurethane was applied to provide UV protection to the epoxy (which will degrade without it). A full 5 coats was applied over a few days to achieve a high-gloss, protective layer.
The bamboo was scuffed with steel wool and then treated with Teak Oil, which is basically a varnish that penetrates into hard wood before curing to water & UV resistant, natural looking finish.
01-FEB-2013
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Here the 68mm English Threaded Shimano bottom bracket is installed.
01-FEB-2013
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Heatset bearing cups installed. This was done using the 2 large aluminum bottom bracket jig plugs as washers with a threaded rod & nuts to compress the bearing cups into the headset. Shown taped off to keep clean until fork is installed.
01-FEB-2013
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Frame now ready for rest of components.
03-FEB-2013
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Frame being weighed at about 3 Kg. This compared very closely to my all aluminum Spot Acme frame at 3.5 Kg (with rear pannier rack & fender still installed).
02-FEB-2013
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Rear wheel seated in dropouts showing integrated brake disc and disc caliper mounting points. Note the white No Turn washer under the axle nut. This is a specific Shimano part for mounting the internal gear hub in horizontal dropouts. Drive-side uses a chrome coloured No Turn washer.
02-FEB-2013
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Detail showing rear disc clearance from chainstay. This was a lingering concern during the build process and I was glad to see no mods were needed to clear the stay.
02-FEB-2013
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Rear Internal Gear Hub with belt drive cog wheel (24T, for CenterTrak Carbon Belt system)
02-FEB-2013
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Side view of rear hub. Note that the 113T belt off my Spot Brand Acme bike did not fit as this frame has a slightly longer wheel base. After confirming the new frame dimensions, a 118T belt was ordered. Note the chrome No Turn washer. The Seat Stay attachment bolt will need to be undone when fitting the new belt into the frame.