Building a Frame Jig

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Building a Frame Jig
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flag Lambert45
Posted: Nov 4, 2018 at 18:48 Quote
Hello to all who take a look at my frame jig build thread. I have been an avid mountain biker for years and I have always been a bit mechanical so here I am building a frame jig so that I can start building my own frames.

This is the material I will be using, it is called T slot framing from 80/20.
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I got the design and inspiration from a youtube channel called Pithy Bikes. He has been the inspiration and mastermind behind my project. He has a video series of a step by step process building his jig as well as frames.
https://www.youtube.com/channel/UCqQaFLkweCgviyj_E0VEy9Q
I will be using his design to build my jig, however I will be changing a few small things.
flag Lambert45
Posted: Nov 4, 2018 at 18:53 Quote
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This is an old motor stand my father had laying around his shop. I figured it would be great for my jig, I just need to clean it up.

Fresh paint
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all built up
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flag Lambert45
Posted: Nov 4, 2018 at 19:05 Quote
The first step to the build was to mount the main jig beam to the work stand. I put the whole rotating plate in a lathe and spun it down to ensure the main beam is mounted to a flat surface.

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The 80/20 comes with pre existing holes in the ends of the material but they need to be taped so that I could mount the head tube beam.

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I had to then drill the holes through the head tube beam which is no easy task I found out. I am using 8-1.25 bolts, so first I drilled the holes for the bolts then I drilled room for the heads of the bolts using a large drill.
flag Lambert45
Posted: Nov 4, 2018 at 19:46 Quote
Next up is the adjustable head tube. The bottom arm will be in a fixed location and the top arm will be able to slide so you can use any size of head tube.

I am using one inch thick 6061 aluminum plate for all of the main fixtures. I milled the pieces down to 40mm so they match the 80/20. This photo is the bottom head tube arm that I grooved so it fits tight in the 80/20 track. I then drilled and taped the plate to take a 8-1.125 pitch bolt.
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The top arm will be the adjustable one so I have to use two pieces and bolt them together. I then install t-slot bolts which will act as the locking mechanisums for the arms.
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Here it is bolted up.
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flag Lambert45
Posted: Nov 4, 2018 at 19:55 Quote
These are the three (two for head tube and one for seat tube) cups I have milled down from two inch 6160 aluminum.

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I still need to mount the cups to the head tube arms.

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flag Beecee336
Posted: Dec 2, 2018 at 17:49 Quote
Looks cool. Keep us updated as you get one jigged up and built!
flag Lambert45
Posted: Dec 2, 2018 at 20:06 Quote
Beecee336 wrote:
Looks cool. Keep us updated as you get one jigged up and built!

Thank you man I really appreciate that. I am a complete newbie to machining and working with the lathe but it has been a fun learning process. I am still a few months out on welding up a frame but I will definitely post it on this build thread.
flag Lambert45
Posted: Dec 2, 2018 at 20:14 Quote
I am now mounting up the seat tube and bottom bracket portion of the jig. This is the backing plate that will mount to the 80/20 as well as the mast for the seat tube and bb.

I have cut out the block and cleaned up the edges in the mill, now I have marked out the mounting holes.

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End mills leave a great look on the material.
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Hear it is all mounted up.
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flag Lambert45
Posted: Dec 2, 2018 at 20:25 Quote
This is the mounting slider for the seat tube cup.
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All mounted up.
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Next I needed a way to adjust the angles on the head tube and seat tube. I milled down some 1in then made the slot for the pinch bolt.
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It required a LOT of milling!
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It came out ok I think. Head tube
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Progress so far
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flag Beecee336
Posted: Dec 3, 2018 at 12:25 Quote
Do you rebuild rear ends at your shop or do you just like to collect lockers and diffs? Haha
flag Lambert45
Posted: Dec 3, 2018 at 20:42 Quote
Beecee336 wrote:
Do you rebuild rear ends at your shop or do you just like to collect lockers and diffs? Haha

Haha, yes we specialize in gear changes front and rear so we have to have a lot of them on hand. Good eye
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