Custom Frames

A Frame is Born

Here you can follow the creation of a DAVE YATES custom frame. If you wish to see more detail simply click on any of the images to view an enlargement.

 

 

Click image to enlarge Every custom frame starts with a consultation with the customer. Dave has a fully adjustable jig that can be used although he prefers to work from the riders existing bike as a starting point for the design.


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Tubes and components are stocked in a variety of types and sizes.
 

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The tubeset and components are selected using the customers order form.
The building of the frame commences with a set of sub-assemblies. This is the chain stay/drop out joint using a jig to position the joint for brazing.

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This is the seat tube/bottom bracket joint being brazed using the main jig.

The head tube/top tube joint in the jig after brazing

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Here you see the forks being brazed in the fork jig

 

The sub-assemblies are carefully assembled in the frame jig which is designed to allow any size or type of frame to be built.

The bottom bracket is the fixed reference and all the other centre lines are adjustable. Co-ordinates are used to set the seat angle and rear drop out centres.

The measurements are taken from the customers order form and are checked and re-checked several times. Once Dave is satisfied the dimensions are correct the joints are fluxed and the triangle brazed together.

 

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The seat stays are fitted as a second operation. They are carefully marked to length and whatever end treatment the customer has specified is applied to the tops. Then they are brazed in place.

 

 

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The "braze ons" are silver soldered in place and the whole job cleaned up by careful use of files, emery cloth, elbow grease and a great deal of skill.

 

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Once the metalworking is finished the alignment of the frame is checked, and any minor imperfections corrected.

 

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The frame is then shot blasted all over before its trip to the paint shop.

 

Within minutes of the shot blasting operation the frame is sprayed with a coat of acid etch primer that provides a secure base for the paint system.

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Several coats of colour, depending on the colour scheme, are applied building up the thickness to provide a tough durable coating after stoving in the oven.

 

 

Click image to enlarge Once the paint has been stoved the transfers and any lining required are applied and a coat of clear lacquer is sprayed on to seal it all. Click image to enlarge

 

 

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Before the job leaves the workshop all the threads are tapped for easy assembly of the bike.

 

And Finally......... the finished bike ready to be ridden off into the sunset !!
 

 

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If you are feeling inspired and fancy designing and making your own custom frame click here.

 

If you would like to know more about frame design considerations click here to read an article written by Dave Yates and published in Arrivee - the Audax UK magazine