We just got a MIG welding station at my studio, and I've had an idea for an unusual bike fork for a while, and now I want to build it. If you have any experience in the matter of welding bikes and forks etc. I'd greatly appreciate some help - I've only done a tiny bit of welding, and none of it was bike-related. I can and probably will practice a bit before attempting the fork. I can pay you in skillshare or food or bike parts or cash.
Not a problem - I have 4 or 5 welders, depending on how you count, and would be happy to give some instructions on this. One welder is set up for thin wall steel and would work well. I'd like to see it get some use as I don't use it often. I want to finish the welding on a GT1/land speed tube chassis this week, so I will be around. jcm250b at juno dot com
maybe obvious, but otherwise friendly disclaimer:
Perhaps I'm missing something, but it seems to me that Jacob has the welding thing down, but it's unclear as to whether that includes welding bicycle frames, and specifically, forks. Considering it's a fork, getting it right is paramount to you not having to pick up your teeth off the pavement.
If I'm mis-reading and Jacob has skills in fork fabrication, then go nuts. Otherwise, if all you want is a one-off fork, contact an established builder and have them do it for you. They have the skills, tubing, jigs, other tools/ etc to do it right, and it'll save you time/effort/possibly your front teeth.
I think anytime the phrase "unusual x" is used, safety goes out the window
John, out of curiosity, what's your metal fabrication background?
I have only talked with Jacob briefly, but I am willing to bet that someone with experience building race cars has enough knowledge to build a fork. Keep in mind performance isn't what is being sought.
I don't know where people get the idea that standard use bicycle equipment goes through outstanding stresses.
Legitimate concerns, no doubt.
I welded the fork on the bike I rode to work today. Hasn't broken yet despite a few years of Pgh potholes, bunnyhopping, etc. John, if you want to check out something a little more complex than a bike fork that I've welded, feel free to stop by and check out the 14 point roll cage/race car chassis I am finishing per SCCA GT-1 specs. I don't mean this in a negative tone, but I wouldn't be planning to take it land speed racing if I were uncomfortable with the work.
No doubt, though, a fork must be right. For liability reasons, I won't be welding anyone's fork, but am happy to provide some basic instructions on MIG welding, proper tube prep, proper joint fitment, jigging to control warpage, and access to the equipment for some practice. There are also some issues with MIG welding thin wall tube, especially chromoloy, and I can share what I know. I'd rather share what I know than hear of the consequences of someone doing this without some basic instruction.
Don't forget your post-weld heat treatment.
In the few test-to-failure test I've done, all the failures have been in the heat affected zones surrounding the weld, not the actual weld itself.
Just to be clear, this is not a fork I expect to ride a great number of miles or faster than 10 mph or so. It's more of an experiment and a way to improve my welding skills and learn a few things about bicycle manufacturing prior to (eventually maybe) trying to weld some things I'd use day to day.
