Introduction

[Sling Blad]

Thought I would introduce myself........

I'm down here in SC, just downloaded the plans and have begun the process. No welder, but I have a lead at a local machine shop that "specializes" in odd projects. I have a meeting with the owner tomorrow.

Prepare for multiple questions! NEW GUY!!!!

I've got parts and pieces on order and already have the "reclaimed" bike parts.

Here's the plan. Build a DW, and then add my E-kit (sometime down the line), possibly adding a fairing later for all weather commuting. It's a short trip for me (12 miles round trip) so it should be an easy go.

Hardest things so far, finding a supplier of bearings and steel. Kinda hard to find down here. The internet is a wonderful thing.

I've been riding my regular MB with the E-kit for about three weeks now. My SO rode it with the kids in a trailer tonight and she was all smiles. I can't wat to get her on the DW. I'll probably be building one for her very soon.

Another tip...Sir Joey will not part with his favorite ride!

Pictures of progress will be coming, only thing I've got so far is a work bench full of bike parts and a pile of used up frames that have been hacked.

Question: (since I know nothing about welding) Would braze welding be as effective as MIG?? I can braze, but not MIG. Any opinions.

I've been lurking for about two weeks and just now joined. Wish I would have found this site prior to the E-kit! But, the E-bike is great fun and the kids love the speed!

Here's to anticipated great fun and the learning process!!!!

[AtomicZombie]

Welcome!

Although there are always ways to do just about anything, I am going to say no to the brazing. Unless you make a lot of changes to the frame design, this one will not hold together if brazed.

Brad

[Sling Blad]

Well, since I can't weld (no equipment and no knowledge,) I went to a local fabricator today with my set of plans and all of the mods. He's also my local supplier for steel and machine shop. Nice crew and a good looking shop. After about 30 minutes of sheeting through the plans and discussing options, I asked the question.......

"How much do you estimate it will cost to do only the welding portion?"

I have the tools to do cutting, prep, and clean-up.

His answer.....$1000 to $1500! That's three times the price of me buying a hobby MIG and doing it myself!!!! Does that sound high to anyone???? Knowing all of that, having a professional welder do the important parts does make a difference, but dang, that much. Seems a little high to me???

Got my first piece of steel to start cutting and prepping. Bearings will be here in a few days.

Anybody setup a DW with a 26" front??? Just thinking for future mods for my kit. Seems like angles and lengths at the front end will be the only issue. Any ideas???

[n9viw]

First off: WELCOME TO THE KREW! You're in the right place if you want to learn about making your own bike rig. Brad's plans are top-notch, and the combined knowledge of the builders here rivals the armchair warriors of the other sites!

As for your welder's quote, that sounds about right for a one-off contract job. Remember, since he's your source of supply AND work, that means he'll be sourcing all the steel, doing all the welding, etc. He'll probably also have to do a little fitment, since you probably don't have access to precision equipment. Also recall, using the fee he charges you, he has to pay his electric bill, his consumables, and his CYA (liability) papers.

With all that aside, you'll pass him a set of plans and some cut tubing, he'll pass you a built bike frame. Pardon my frankness, but where the hell is the fun with that?! :lol:

The WHOLE POINT to this site is that REAL PEOPLE make REAL BIKES with their own REAL HANDS, with the lowest cost and highest ease of operation possible; that's the way Brad intended it. At one point or another, some of us have had to pass a piece off to a machinist to have them custom-cut a hub or adapter for us, but by and large, from parts sourcing to final touches, WE do all the work, with ordinary hand and power tools.

No, it's not easy. Talk to Sir Joey about the heat, or to TheKid about how many adjustments and rebuilds it takes so your back doesn't hurt, or to Ggriffin and GBBWolf about how much you have to scale up your plans to accommodate your size. Talk to Pagan Wizard about the lack of space and tools (and knowhow ;) ), to Back2Life about sacrifices made for funding, or ANY of us about getting good supplies.

My suggestion: use the SEARCH function on this site before asking too many questions; chances are, not only has it been asked, but it's likely been answered, several times in several different threads. Look through the Builder's Corner, garner ideas for your build, and if you don't see answers for your particular questions, go ahead and ask.

Secondarily: Look for sales, and pick yourself up a good flux-core wire-feed welder. A lot of good has been said for the Hobart 125EZ, the 140EN, and even the 220V Harbor Freight model. Get a good auto-dimming mask and a slab of steel, and start drawing lines. Get used to the welder, and make sure your results match your attempts.

Once you've gotten good beads, start sticking things together. Papa recommends "coupons" - little plates of steel in the gauge you plan to be welding - to better inspect your weld quality. You can see the backside for penetration and HAZ, cut it apart to check the depth and spread.

As for setting up the DW witha 26" front, do a search here for "DeltaRunner" - it's already in the works, plans are coming soon. Yes, the front end changes some, but the majority is unchanged from the DW.

Good luck, and TAKE LOTS OF PICS! :D

[KoolKat]

Welcome, Sling! Glad you've joined the Atomic Zombie madness. Be prepared, though. This stuff is highly addictive!

[Odd Man Out]

the combined knowledge of the builders here rivals the armchair warriors of the other sites!:D

The combined knowledge found on this site does not "rival" that of the armchair warriors found at other sites. The combined knowledge to be found on this site could run countries!!!

[Trailblazzzzzer]

Take the plunge, run upto Tractor Supply or Harbor Freight check out their Mig Welders and a their Solar powered Welding Helmets.
Or get online and find a nice 135 amp 120 volt welder.
Mig Welding is not at all difficult to get the hang of.
(the Lincoln welder has a cool cheat sheat on the inside cover on the machine.)
If you like the idea of building your own creation...
... you will love making arcs & sparks.
Before long you will be using all your beer and cigarette money to fund your new obsession.
Have fun
Davo

[John Lewis]

........Before long you will be using all your beer and cigarette money to fund your new obsession.
Have fun
Davo

Ain't that the truth! :D

John Lewis

[ggriffin924]

I got my welder off of craigslist for $200, and its for multiple projects not just the bike stuff. I did start with gas-less but I didn't like the splatter and quality of what I could do with the gas-less, I have heard that once you have had practice either is ok. My welds look a ton better now then when I started, and I had to redo some of the welds as many as 3 times before I was happy when them. But thats what a cutting wheel on the grinder is for. Before starting the Delta Wolf I had never welded anything, only experiece I had was sweating copper pipe for plumbing for my own home repairs. So I think anyone can get proficient at it, given only a little practice. I'm only bummed because I had to take my wolf apart last night for painting, all the welding is done and its just paint prep sanding and waiting.

-Griffin-

[jimFPU]

I'm with 924!!

I got an even cheaper ($60) brand new flux core welder from CL. Never welded before in my life. Posted pics here of my first few welds and got some feedback.

Next thing you know I was here...
http://forum.atomiczombie.com/showthread.php?t=1118

[Sling Blad]

n9viw, I'm right there with ya' and whole heartedly agree. You're right. Building something with your own two hands is the way to go. You're definately right, his tools, his people, and his skill....he sets the price.

That's how I convinced the wife to let me get a welder last night. I'm gonna start with a gasless from my local hardware store. Probably not the top of the line, but it will get me started in the process. This will be a long learning and building process, but I've got time. I'm a "hands on" learner anyways, so this will be right on my ticket.

It just makes sense anyways. I'll probably be building another for my wife once she rides mine.

So, it's off to the hardware store this weekend. I'm in luck.....a guy who works in my building is a certified welder and has offered to help get me started (provided I help him move his washer and dryer - seems like a small price to pay.)

So, this weekend, purchase and setup the welder, cut tubes for chapter one, prep them, then start practicing on scrap. Hopefully, within a few weeks, I'll be assembling the rear-end.

My goal, have the DW together, tested, painted and ready to go for spring.

I'm on everyday learning something new or viewing readers rides! I can't wait to get this DW on the road!!!! thanks for the help!! More questions to follow.

[SirJoey]

Welcome to the Krew, SB!

Where 'bouts in SC are you, anyway? I'm in the NW corner of the state, myself.

http://img384.imageshack.us/img384/7131/sirjoeysigmedij1.gif

[Sling Blad]

Sir Joey,

I'm in the Slow-country......whoops, I mean the low country...Beaufort to be exact.

[Sling Blad]

Well, my bearings came via UPS tonight. The are sweet......set screws, grease zerks, and they are a really nice blue color. I can't wait to get started. Welder purchase this weekend, and cutting begins Saturday! (well, okay, maybe Friday night!

[n9viw]

That's how I convinced the wife to let me get a welder last night.

:eek: Now THAT'S the power of persuasion! Wow, do you do seminars?! :D

Good show, SB! You've opened the door to a wide, grand world of creation... watch out, though- people may ask you to build THEM one, and if you say yes to one... :rolleyes: Could have your hands full in short order.

Looking forward to another AZ creation take shape! Now, if I could only get off my duff and build one myself... :o

[KoolKat]

Uh oh, Sling's been bitten badly by the building bug. And he'll never be the same again...YAY! ;)

We're here to help you along the way. Don't hesitate to ask.

[Sparky]

again, i'll say it...

welcome to the insanity :)

ready by spring? heck, with that attitude, youll have it rideable within a month . :D

[Sling Blad]

Here's an update.....

I got the welder Friday night, pulled the books and manuals and started the process. I also bought gloves and a better flip down helmet with an auto darkening lens. That little "hold with your left hand mask" - actually a sheild , not even a mask, wasn't going to work for me. I just have a feeling I'm gonna need both hands.

Today, I cut and tested the fit of the first few pieces for the rear frame assembly. I learned two things today.....

1. When cutting with a 4.5 inch cutoff wheel, take your time. Let the cutter do the work. (Best purchase of a tool so far. It would have taken me all day to cut these with my hack saw. I had them cut in under 30 minutes.)

2. Don't use a cutting wheel at about knee height while wearing shorts if you have hairy legs. Now I have one hairy and one not so hairy. lesson learned, right!

All told, the pieces came out nice. I have some cleaning up to do and some filing and grinding before my first welds, but I now have some scrap to practice with and it's only a matter of time before I'm laying my first tacks and beads!

[Sling Blad]

Got the welder setup and a buddy came over for 30 minutes while we ran beads and practiced joining scrap. This was much easier than I originally thought. Took me about an hour to set everything up (I actually used the manual!)

My first beads were ugly. I had to much speed and to much heat (even according to the inside panel for starters) but, by the time he had to go, I had the idea and joined some scrap that held both our weights.

Now, to finish the clean up for the pieces from chapter one and begin the fun. I'm on the lookout for a bench or something to elevate the work.

Lessons learned today.....

1. Welding on the patio concrete is hard on your back.

2. When joining metal, it becomes hot for some reason. Wear gloves at all times.

Ends state, within an hour and a half, I now have a good understanding of how things work, and can actually join metal. Time to start constructing!

[TheKid]

Be careful when welding on concrete or bluestone, and possibly other types of stone as well. There's a tendency for small pieces to pop and fly when extreme heat is applied.

[macka]

Sling,

I've used 2 saw horses and joined them with 2x4's and covered it with scavenged bbq grills for light work. You just have to have enough support underneath. Also wear pants and work boots if at all possible, it sucks doing the weld spatter shuffle (thats where you get some spatter on the foot). You'll be doing good welds in quick time if you practice daily. You're going to have to put your scavenging goggles on and start looking for other bits to weld. In time you'll probably pick up an arc welder so you can weld other metals in other projects without having to buy different reels and tips. It also pays to see if you can find a college night course to learn all the types of welding.

[Sling Blad]

I joined the first pieces of the back section last night. Took me quite a bit, and it looked rather sloppy to some of the welds I've seen on here. I ground it down a bit tonight to clean it up and it came out surprisingly well. I looked through the tubes to check for penatration and it appears (to my untrained eye) that I did a decent job.

This weekends plan is to finish the back frame assembly and cut the next few tubes for the frame. Then, hopefully, get them together and move on to hubs and wheels.

I'm looking forward to getting to the rolling frame stage, but I still have a long way to go.

Lesson learned from yesterday:

1. Welding slow is better than finishing quickly!

[gbbwolf]

Bird poop welds are quite common here.
Good penetration is always good.
Just ask your significant other.

Seriously though welding pretty is an art form but like many forms of art it can be a challenge.

Look at all the different types of painters just because I like picasso doesn't mean it isn't crap to someone else.

Main thing is solid welds Prettiness will come with time.

By your 5th or 6th build your welds will look less like picasso and more like rembrandt.

Nelson