Disc cross forks

It's hard to know how beefy to build a disc-specific cyclocross fork, especially when you know it's going to be ridden on trail, over big washboards, through winter, and with room for fenders. You want to make it light and ride smooth but strong enough to last. I first built a lugged-crown fork (Nova 7deg... Continue Reading →

PJMac’s frame progress

I'm 3/4 done building a 29er frame for Paul, mastermind of Cross Propz - portable cyclocross barriers for training rides and practice. Pretty ingenious design where you can literally thrown it on the ground and the bungee cord connected PVC pipe barrier nearly self-assembles itself in seconds. Paul has been waiting a long time for... Continue Reading →

Cannondale Lefty on custom frames

It's strange having this blog come up more than any other site for framebuilding information when I Google anything from welding to mitering questions.  I KNOW other builders blog about this stuff but maybe Google likes WordPress blogs better than Blogger blogs. That'd be funny since Google owns Blogger.  I hope some people find this... Continue Reading →

Fatbike fork for Dynamo hub

This fork is for loaded dirt, snow &/or sand touring once attached to his Surly Necromancer frame. It's got more braze-on's than most touring frames! It's got three bottle bosses on each leg for Salsa Anything cages or for water bottle cages in one of two positions (high/low). It's got one bottle boss on the... Continue Reading →

Knard-sized segmented forkage

I'm building a fork (and next, a frame) for the Surly Knard tire and 50mm wide rims.   I am super psyched for these tires to be released, sometime in December. In March of this year, after a couple days with TB in Durango riding fatbikes, I emailed Kenda's to try (beg) them to create a... Continue Reading →

Lugged Cross fork for Jim’s frame

I used the Nova 7 degree offset fork crown for this fork. I dig this look and it's still pretty light and stiff (1.9lbs/880 grams with a whopping 11" of steerer left).  The crown is drilled out to accept a 'fork crown cable hanger' to reduce brake and fork chatter when slamming on the brakes.... Continue Reading →

Fatty fork for my upcoming Fatbike.

It's officially winter, there's constant snow on the trails, and I'm going to try to ride my bike more this year. In previous years, i commuted a few days a week the 20 miles & ~3000ft elevation loss to Boulder with studded tires on cross or MTB depending on conditions.   On the weekends I skied... Continue Reading →

CX fork numero uno

My first cross fork is all done! It went pretty smoothly. I got the Dedaccai unmitered blades, steerer, & dropouts from Nova. I dig the dropouts, they are plug-style and have a breather hole already drilled. They are slight - very light...but should be great for a cross fork. I silver brazed the dropouts in... Continue Reading →

Fork alignment

I am almost finished with my girl's fork for her new steel 26"-wheel frame.  For this fork I used True Temper FB-4 fork blades since the axle to crown length is only 432mm.  There's enough room for a 29er too if she ends up wanting a big wheel up front.  I love the look of... Continue Reading →


Finished up Hayride's segmented fork today.  I'm thinking it's lookin pretty darn good! From where I was a year ago, to where I am now...it's been a long trip but I can finally say I feel comfortable with my fabrication to make stuff for friends.  He's been riding my 1st frame for a few weeks... Continue Reading →

Hayride’s fork is nearly done

It's been busy here doing mapping work lately so haven't been updating this blog, but i have been doing some fabrication. I've got Hayride's segmented fork nearly done to replace his Surly Karate Monkey fork.  I mimicked the geometry (468 axle to crown, 43mm offset) which keeps it at 75mm of trail.  Hopefully this style... Continue Reading →

Fork 5 for frame 3 is done

I finished up my first 'regular' segmented fork yesterday (no sleeves). I spent the better part of two days building and painting it before mounting it up to the short-stay 29er last night. I don't practice my tig welding as much as I used to but I still think they turned out pretty good.  I... Continue Reading →

Segmented fork, take 2

After bending my first segmented fork when seeing how it'd hold up, I got right to making #2 since I don't have a fork for the RivBomb frame to ride yet. I swear, what takes most people 4 hours takes me 4 days. Of course, I tend only to get a few hours a day... Continue Reading →

Testing 1, 2, 3…

I killed my first segmented fork....on purpose.  I wanted to test the strength of the fillet brazed sleeves since when I cut up a couple of test brazed sleeves thebrass was only getting down 1/2" at most from the edge of the sleeve.  I'm pretty sure it's not my brazing technique, since there is a... Continue Reading →

Segmented fork build progress, tacked!

I got my first segmented fork all tacked up today. Here's a pictorial of how it went.  Thanks again to Waltworks for posting a how-to back in 2007 on his blog.  I don't know how i'd be doing this without that web-help.  Yesterday I welded the dropouts to the legs.  I should've practiced more before... Continue Reading →

Fork #2 done

The first adjustable-rake fork is done!  I haven't put in tension screws yet since the track SS dropouts are narrower (7mm) than the sliders (9mm) which have the same 4mm bolt tapped into them that I was gonna try and put in the track drops.  If I try it, I'll have to go with a... Continue Reading →

Legs are welded

Second, the first pass on the front, no pulser Another step completed in the fork build tonight. Slow build because made a wall in the garage to separate the 'garage' from the 'shop.'  The shop will get heated, the garage won't...should save on $ and also i'll have a cleaner workspace.  Anyways... I tacked the... Continue Reading →

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