E03JSB - Zinkensdamm

This is the first frame I've built for someone other than myself. The project started when my very good friend Jesper learned that I had (finally) started to build frames and he contacted me about building him a BMX frame.
Being that I don't have a fully equipped workshop with the tools needed to bend tubes etc, I decided to track down a tube set with already bent tubes for the chainstays and seatstays. I approached S&M and was able to buy the material I needed from them. The tubeset used is the same as the one used in their BTM frame.

Building this frame presented some new (to me) challenges since it needed removable brake mount inserts and the previously mentioned grind guards, plus a downtube gusset - all features I had not done before. Because of this I had to switch up the build process a bit and start by brazing the seat stays as a subassembly in order to be able to drill the holes needed for the brake mount inserts and get them nice and square in the right spot. The downtube gusset was easier than I thought it would be. The biggest challenge was the chainstay guards. It took me a fair few hours to shape them and silver solder them into place - stainless steel sure is a different beast to work with compared to cromoly.

Unfortunately I lost all my build progress photos due to a phone malfunction, so the only photos I have are the ones I've been uploading to Instagram. Here's a gallery showing the build progress:

The frame features Jesper's choice of geometry with the chain stay length optimised for the gearing he usually runs. Jesper mostly rides pegless and does a fair bit of grinding on the pedals and cranks, so he wanted me to incorporate chain stay guards to make them a bit more resistant to denting and grind damage.

 This is the kind of damage that Jesper's frame has seen in the past.

This is the kind of damage that Jesper's frame has seen in the past.

 Stainless steel grind guards should help protect the structural integrity of the chainstays.

Stainless steel grind guards should help protect the structural integrity of the chainstays.

While building this frame I took into account the things I had learned during the previous builds. This frame had a few new (to me) challenges since it needed removable brake mount inserts and the previously mentioned grind guards, plus a downtube gusset - all features I had not done before. Because of this I had to switch up the build process a bit and start by brazing the seat stays as a subassembly in order to be able to drill the holes needed for the brake mount inserts and get them nice and square and in the right spot. The downtube gusset was easier than I thought it would be. The biggest challenge was the chainstay guards. It took me a fair few hours to shape them and silver solder them into place - stainless steel sure is a different beast to work with compared to cromoly.  

After all the brazing was done, all that was left was some (read: a lot of) finishing work and a few layers of clear coat. I'm quite happy with the end result and it was a great learning experience. It's been a long build process (sorry Jesper!) and during the course of it I've identified a few things that I will do differently next time to make the whole process more efficient and straight forward.

I can't wait to get it shipped over to Sweden so Jesper can build it up. Really looking forward to seeing it getting some use!