Tuesday, December 22, 2009
Wednesday, December 16, 2009
Dec. Happenings
Once again, I'm struggling to keep the blog up to date! I'll try to fill everyone in on the latest goings on at Ellis.
This past weekend I had a rare Sat. off from Ben's, so I decided to ride the Milwaukee Santa Rampage. I hooked up with Jason at his shop, and riding along were his friend Jay, and Jon (of Jonny Cycles) from Madison. I had the camera battery all charged up and ready, and I then proceeded to leave it in my backpack after getting all my warm clothes on. So, unfortunately, no pics Santa Rampage. Suffice it to say, it was a blast riding around Milwaukee with about 200 other folks all dressed as either Santa, elves, or other festive critters! I was the buzz kill guy in a red cycling jersey, as I hadn't planned ahead much for the ride and it ended up as a spur of the moment decision to ride. Next year!
As for Ellis Cycles, I finished up Caitlin's frame last week and dropped it off with Jason last Sat.
All the tubes mitered up and ready for the fixture. I hadn't done any work yet on the fork crown, and was noodling over how to make it hang with the frame stylistically. I worked out a cool pattern that's pictured below, and it ended up being one of my favorite details on this frame.
The head and seat lugs are a set of Silva? lugs I got from Ceeway a while back and I've been waiting for a project to use them on. They're for standard gauge tubes, and very minimalist, except for the bands on the head lugs. I carved them back a bit and added the circular cutouts that are becoming one of my favorite motifs.
Of course, the Inspector had to make an appearance to check things out.
Finally, the seat lug, with some tidy sidetack seat stays. If you look closely, you can see the stainless waterbottle boss I added on the inside of the stays for mounting a rack. Caitlin wanted the flexibility to run a rear rack, but this way when it's not mounted, the mounts are not nearly as noticeable. Plus the stainless bosses won't get chipped and rusty from taking the rack on and off. I added stainless washers on the dropout eyelets as well.
This past weekend I had a rare Sat. off from Ben's, so I decided to ride the Milwaukee Santa Rampage. I hooked up with Jason at his shop, and riding along were his friend Jay, and Jon (of Jonny Cycles) from Madison. I had the camera battery all charged up and ready, and I then proceeded to leave it in my backpack after getting all my warm clothes on. So, unfortunately, no pics Santa Rampage. Suffice it to say, it was a blast riding around Milwaukee with about 200 other folks all dressed as either Santa, elves, or other festive critters! I was the buzz kill guy in a red cycling jersey, as I hadn't planned ahead much for the ride and it ended up as a spur of the moment decision to ride. Next year!
As for Ellis Cycles, I finished up Caitlin's frame last week and dropped it off with Jason last Sat.
All the tubes mitered up and ready for the fixture. I hadn't done any work yet on the fork crown, and was noodling over how to make it hang with the frame stylistically. I worked out a cool pattern that's pictured below, and it ended up being one of my favorite details on this frame.
The head and seat lugs are a set of Silva? lugs I got from Ceeway a while back and I've been waiting for a project to use them on. They're for standard gauge tubes, and very minimalist, except for the bands on the head lugs. I carved them back a bit and added the circular cutouts that are becoming one of my favorite motifs. 
Of course, the Inspector had to make an appearance to check things out.
A shot of the head lugs and fork crown. The crown is a Long Shen LC 17, and it starts out with two symmetrical points on the side. I decided to add the circular cutout and make the points a bit more asymmetrical to mimic the lower head lug. Unfortunately, I don't see this lug set listed at Ceeway any more, but I may have to ask if he can get them for me. For smaller frames, I really like this pattern and look.
Finally, the seat lug, with some tidy sidetack seat stays. If you look closely, you can see the stainless waterbottle boss I added on the inside of the stays for mounting a rack. Caitlin wanted the flexibility to run a rear rack, but this way when it's not mounted, the mounts are not nearly as noticeable. Plus the stainless bosses won't get chipped and rusty from taking the rack on and off. I added stainless washers on the dropout eyelets as well.
Cheers,
Dave
Saturday, November 28, 2009
Eduardo's Finished Frame
Eduardo's frame is on it's way to Colorado on Mon., here's some finished photos.
I wanted Drew to take a shot of this detail on the underside of the dropouts. I've been finishing them this way for a while, but haven't had a photo of it yet. I make a point on the bottom face of the dropout and then this gets masked along with the dropout faces. This takes care of the two most commonly chipped areas on the dropout.
The polished stainless head lugs with the head tube logo painted on. Jason has mastered the plotter, so now my logos are paint rather than the black and white decal. This way, they can be customized to match any paint scheme!
Finally, the polished fork crown. I like this shot, if you look closely in the reflection, you can see the frame sitting on the table opposite. Pretty shiny!
More soon!
I wanted Drew to take a shot of this detail on the underside of the dropouts. I've been finishing them this way for a while, but haven't had a photo of it yet. I make a point on the bottom face of the dropout and then this gets masked along with the dropout faces. This takes care of the two most commonly chipped areas on the dropout.
The polished stainless head lugs with the head tube logo painted on. Jason has mastered the plotter, so now my logos are paint rather than the black and white decal. This way, they can be customized to match any paint scheme!
Finally, the polished fork crown. I like this shot, if you look closely in the reflection, you can see the frame sitting on the table opposite. Pretty shiny!
More soon!Dave
Tuesday, November 24, 2009
Kevin's Finished Frame #24
Just finished up Kevin's frame yesterday afternoon and dropped it off with Jason. A very classic, simple road frame.
I tried a new bottom bracket on this one. It starts out life with fleur de lis' on all the points and a couple points on the sides of the down tube and seat tube. I carved it back a ton, and I'm pretty happy with the finished shell. I always add a second drain hole with the cable guide mounting hole.
The full frame and fork. Kevin's going to have it painted black with a white panel on the down tube, black lettering and a white head tube logo. Very stripped down and minimal.
I resisted using this seat lug for a while, as it reminds me of the Serotta Atlanta, which was the lower end model I built quite a few of during my time at Serotta. The Serotta lugs had an "S" cast into the flat side panel and I just got tired of the look. Last year I decided to use this lug on my "Modern Classic" for the NAHBS, since it matched the head lugs and it is ideal for mounting the fastback style seat stays. Since then, I'm warming to it's shape, and I'm using it more and more with the 1 1/8" head lugs from Long Shen.
Some added touches in the lug corners, and I've carved the band a bit also.
The Ellis dropouts with skinny seat stays attached! When I use these dropouts with 953, the stays really engulf the dropout ends, but with a standard 14mm double taper stay, the ends are so dainty! I must say, I prefer the thinner look, and they ride really nice too.
A final shot of the fork dropouts, nice and tidy!
I tried a new bottom bracket on this one. It starts out life with fleur de lis' on all the points and a couple points on the sides of the down tube and seat tube. I carved it back a ton, and I'm pretty happy with the finished shell. I always add a second drain hole with the cable guide mounting hole.
The full frame and fork. Kevin's going to have it painted black with a white panel on the down tube, black lettering and a white head tube logo. Very stripped down and minimal. 
I resisted using this seat lug for a while, as it reminds me of the Serotta Atlanta, which was the lower end model I built quite a few of during my time at Serotta. The Serotta lugs had an "S" cast into the flat side panel and I just got tired of the look. Last year I decided to use this lug on my "Modern Classic" for the NAHBS, since it matched the head lugs and it is ideal for mounting the fastback style seat stays. Since then, I'm warming to it's shape, and I'm using it more and more with the 1 1/8" head lugs from Long Shen. 
Some added touches in the lug corners, and I've carved the band a bit also. 
The Ellis dropouts with skinny seat stays attached! When I use these dropouts with 953, the stays really engulf the dropout ends, but with a standard 14mm double taper stay, the ends are so dainty! I must say, I prefer the thinner look, and they ride really nice too. 
A final shot of the fork dropouts, nice and tidy! 
Should have pics soon of Eduardo's frame. If you've been watching the blog, you'll remember he had the compact frame with stainless head lugs, seat lug and fork crown. He chose a beautiful shade of orange for the frame and it's completed with white panels and red pinstripes and Ellis logos. Quite stunning!
Cheers,
Dave
Ellis in Patagonia
Gotta hand it to my brother Steve, he's a tireless supporter of Ellis Cycles and the proud owner of last year's NAHBS bike! Some of you may know that he works for Patagonia in Ventura, CA. Well, with his help and some contacts in the Chicago Patagonia store, I've got my personal road bike on display through the holidays at their store.
http://www.patagonia.com/web/us/patagonia.go?slc=en_US&sct=US&assetid=1936
I've got a kinda blurry shot of the bike that was forwarded along below;
If you're in Chicago, go check it out!
http://www.patagonia.com/web/us/patagonia.go?slc=en_US&sct=US&assetid=1936
I've got a kinda blurry shot of the bike that was forwarded along below;
If you're in Chicago, go check it out!
Tuesday, November 17, 2009
Kevin's Road Frame
Kevin has been waiting patiently for news of his frame for a few months, and I tried to take more pictures of the process for him.
A bit out of order here, but below are all the tubes, mitered and the fork after brazing and a good soak.
Mitered tubes, set up in the fixture.
Below I've got all the tubes, lugs, dropouts and bridge laid out and ready to start.
I've raked the blades, slotted, brazed the dropouts and cut the blades to length. Ready for...
The torch!
I've cut some circles in the lug corners and just modified the lugs a bit. Plus all the points have been sharpened up.
A bit out of order here, but below are all the tubes, mitered and the fork after brazing and a good soak.
Mitered tubes, set up in the fixture.
Bottom bracket dry fit.
Friday, November 6, 2009
Chad's Triathlon frame
Chad called me early this summer to ask if I could build him a unique triathlon frame. He was tired of having the same bike as everyone else week in and week out at all the races. While a steel tri frame would be unusual enough, I decided to use a technique called bi-laminate for the joints due to the unusual angles that a tri frame presents. I learned how to do the bi-laminate style while I was starting out at Serotta, but we just called them "half lugs"! Bi-laminate sounds so much more refined, right? ;-)
I've got the fork built, it's getting chromed, and then the rest of the tubes and lugs prepped and ready to go. Chad also wanted to go with polished stainless chain stays, I've got the parts above, but I brazed the main diamond up first.
Here's the finished frame, bi-lam lugs, aero seat stays, and stainless chain stays and dropouts.
I think Chad will be the only guy at the races with a frame like this!
I did a slightly different treatment for the seat stay ends, hopefully this will make it a nice clean mask line for the paint to polish transition. The stays and dropouts will be polished, but the tricky thing is, how to do the transition to paint.
Down tube lug with barrel adjuster and shifter stops on the down tube.
Seat lug with the massive aero seat stays attached.
Top tube lug.
OK, these last couple are some shots of the next frame in the quene, I got a start on it yesterday. Pretty standard road frame, some small lug carving and it'll have a stainless drive side chain stay and a chrome fork. Should be pretty classic.
I've got the fork built, it's getting chromed, and then the rest of the tubes and lugs prepped and ready to go. Chad also wanted to go with polished stainless chain stays, I've got the parts above, but I brazed the main diamond up first.
Here's the finished frame, bi-lam lugs, aero seat stays, and stainless chain stays and dropouts.
I think Chad will be the only guy at the races with a frame like this!
I did a slightly different treatment for the seat stay ends, hopefully this will make it a nice clean mask line for the paint to polish transition. The stays and dropouts will be polished, but the tricky thing is, how to do the transition to paint.
Down tube lug with barrel adjuster and shifter stops on the down tube.
Seat lug with the massive aero seat stays attached.
Top tube lug.
OK, these last couple are some shots of the next frame in the quene, I got a start on it yesterday. Pretty standard road frame, some small lug carving and it'll have a stainless drive side chain stay and a chrome fork. Should be pretty classic.
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