This is how I make bikes. More or less.
Updated July 2020. My process is always evolving and improving, so the steps listed here may be slightly different from what I do now.
Have a conversation with the customer.
Design frame geometry and chainstay layout and print drawings.
Order material and machine parts (dropouts, head tube, brake mount, etc.)
Ovalize top tube. Dimple chain stays and bend seat tube for tire clearance if necessary.
Miter seat tube, top tube, and down tube and drill water bottle boss holes
Drill vent holes for welding
Fabricate chainstay sub-assemblies
Fabricate wishbone seatstay sub-assembly
Tack weld frame in fixture
Pull the tacked frame out of the fixture and weld it together
Rough alignment check
Add all the bits and bobs. Brake mounts, water bottle bosses, fender mounts, cable guides, rack mounts, seat post clamp, etc.
Face, chase, and ream bottom bracket, head tube, and seat tube.
Final frame alignment check
Mill seat tube slot
Take frames to the powder coater or painter
Once frames get back, face off powder/paint from bearing surfaces and spray rust inhibitor inside the frame
And that’s it. Ready to be built up with some cool parts and taken for a ride.
Head over to the Gallery page to see some nifty completed builds