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  1. #1
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    DIY Project - Headtube Modding - Phase 2

    I had some free time today and got started phase 2 of my DIY headtube mod on my bike so I can safely use a tapered steerer fork when it was originally designed for a standard fork.

    If you guys weren't following this was phase 1:
    Today's DIY project...

    So....continuing from Phase 1

    Sanded down the gel coat and got down to the carbon fiber matrix of the head tube, & scuffed up the metal of the headset adaptor.


    Cleaned and proceeded with the first layer of e-glass (fiberglass) anti-corrosion layer bonded to the raw aluminum of the headset adaptor. Hands were sticky at this point so gave up on pics. LOL ... Continued to lay up unidirectional 12K carbon fiber tow (from a roll), followed by a 2x2 twill strip, more 12k tow, another strip, and more 12k tow. Finally pulled plastic wrap over it to compact all the layers.



    ...(im)patiently waiting for everything to cure...... looking at project bike #3 in the back considering what to start on next.....


    More updates later

    -S

  2. #2
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    Reputation: b-kul's Avatar
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    crafty man

  3. #3
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    Great job!

    Now that it is 12 hrs. ago, both the epoxy on your hands and the bike, should be hardened enough to shoot a pic of the result?

    Magura

  4. #4
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    ok ok ok ... I had to sleep sometime.

    So removing the wrap


    Sanded down everything, especially at the merge between the frame and the new carbon fiber...


    Added a top coat of resin


    Gotta wait for it to cure again and then finish up the work (more sanding, another coat of resin, then polish)

    In the meantime I should go take a shower - I'm itching all over from the CF bits. LOL

    -S

  5. #5
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    Quote Originally Posted by shibiwan View Post
    ok ok ok ... I had to sleep sometime.

    So removing the wrap
    But 14 hrs????

    The end result looks familiar. You should be good to go in another 8 hrs.

    Have you considered post curing? It just might be worth the effort.
    I'd be worried that things goes soft in the sun, if you don't post cure it.


    Magura

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    Quote Originally Posted by Mr.Magura View Post
    But 14 hrs????

    The end result looks familiar. You should be good to go in another 8 hrs.

    Have you considered post curing? It just might be worth the effort.
    I'd be worried that things goes soft in the sun, if you don't post cure it.


    Magura
    No worries - I stole my wife's hair dryer hehe....besides, it's already very firm without the CF reinforcement. If it does go soft it'll go soft when I start riding in summer when hit hits 47-50 deg C and I'll already be dead from heat stroke or something similar.

    -S

  7. #7
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    Quote Originally Posted by shibiwan View Post
    No worries - I stole my wife's hair dryer hehe....besides, it's already very firm without the CF reinforcement. If it does go soft it'll go soft when I start riding in summer when hit hits 47-50 deg C

    -S
    LOL, better do the post curing, before she figures the hairdryer is gone.

    Stuff like that is usually not going down well at my place.
    Whenever something like that is missing, the response is never "have you seen my (insert useful female toy)honey ?", but rather "where is the (insert thing she believes belongs to her, that she can't find)? Have you taken it apart?".
    It's not even a remote possibility that I am not guilty


    Magura

  8. #8
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    Quote Originally Posted by Mr.Magura View Post
    LOL, better do the post curing, before she figures the hairdryer is gone.

    Stuff like that is usually not going down well at my place.
    Whenever something like that is missing, the response is never "have you seen my (insert useful female toy)honey ?", but rather "where is the (insert thing she believes belongs to her, that she can't find)? Have you taken it apart?".
    It's not even a remote possibility that I am not guilty


    Magura
    Over here I'm guilty of not putting things back where they belong... and she goes "No I hid it from you because after you use it I can never find it."

    Here's a better pic


    -S

  9. #9
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    Quote Originally Posted by shibiwan View Post
    Over here I'm guilty of not putting things back where they belong... and she goes "No I hid it from you because after you use it I can never find it."

    -S
    Ok, that beats the logic of Mrs. Magura.

    At least I am mostly guilty, and if not, it will break even with all the cases she never figures I'm guilty of.


    Magura

  10. #10
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    Well done! I am always amazed with people with this kind ingenuity!

    OT...I used to live at Alma and Frye...Love Chandler!

  11. #11
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    Quote Originally Posted by HitmenOnlyInc View Post
    Well done! I am always amazed with people with this kind ingenuity!

    OT...I used to live at Alma and Frye...Love Chandler!
    Waaaaaaaaaay back, I was living near Alma and Southern (i.e. crappy Mesa). Come to think of it, that was a scary area....drug dealers on my street etc...

    Cool... where are you at now?

  12. #12
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    I lived in the Valley for over 20 yrs. Mostly Chandler and Scottsdale, but now in Loveland, Colorado.

    Alma and Southern huh? Funny, I used to manage the Wherehouse on Southern and Longmore....Waaaaay Waaaaay back.

  13. #13
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    Starting to look good.



    -S

  14. #14
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    So, it's test time tomorrow?


    Magura

  15. #15
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    That almost looks factory. Good work.

  16. #16
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    Quote Originally Posted by Mr.Magura View Post
    So, it's test time tomorrow?


    Magura
    Rainy weekend in the desert. I'm staying dry inside.

    -S

  17. #17
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    Dude, I've got to hand it to you, you've got some cahones and ingenuity and some cools toys. Think SpecialED will honor the warranty if anything happens?
    One day your life will flash before your eyes, will it be worth watching??
    MTB Barbados
    My Phantom pics

  18. #18
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    Quote Originally Posted by LyNx View Post
    Dude, I've got to hand it to you, you've got some cahones and ingenuity and some cools toys. Think SpecialED will honor the warranty if anything happens?
    Naah..... technically there's no more warranty because I bought the frame used (and cheap!!).

    If anything I'm going to be the one to do frame repairs if I ever break it.

    -S
    Last edited by shibiwan; 12-15-2012 at 10:32 AM.

  19. #19
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    Quote Originally Posted by LyNx View Post
    Dude, I've got to hand it to you, you've got some cahones and ingenuity and some cools toys. Think SpecialED will honor the warranty if anything happens?
    Yeah, he is one of the hardcore guys, no doubt about that.

    ....and he has more toys than me


    Magura

  20. #20
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    Quote Originally Posted by shibiwan View Post
    Naah..... technically there's no more warranty because I bought it used (and cheap!!).

    If anything I'm going to be the one to do frame repairs if I ever break it.

    -S
    And if it breaks, you got a hotline to the clown that made it

    The hotline to the clown that made it, is part of the reason for me to make stuff. At least I know whom to blame.


    Magura

  21. #21
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    [QUOTE=shibiwan;9971824]...(im)patiently waiting for everything to cure...... looking at project bike #3 in the back considering what to start on next.....More updates later

    -S[QUOTE=shibiwan;9971824]

    ?
    Attached Thumbnails Attached Thumbnails DIY Project - Headtube Modding - Phase 2-picture-60.jpg  

    Last edited by Deerhill; 12-15-2012 at 12:14 PM.

  22. #22
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    Light at the end of the tunnel!

    Final coat & wet sand


    Polished with two grades of rubbing compound


    UV wax polish....


    Put everything back together!


    Whew... that wet sanding was hard work..... going to do something brainless for a while. LOL

    -S

  23. #23
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    That is one good reason to be proud!


    Magura

  24. #24
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    You do outstanding work Man!

  25. #25
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    Quote Originally Posted by HitmenOnlyInc View Post
    You do outstanding work Man!
    Thanks -- only when I feel like it.

    Helps that I own an engineering company that does automotive and aerospace R&D, prototyping, manufacturing, composites, etc

    I oughtta get off my butt and make bike stuff to fund my biking addiction.

    -S

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