Fabricating a Bicycle Frame

I build my frames, racks and stems using one of two construction methods; silver-brazed lugged method and “fillet-brazed” (bronze-welded) “lugless” method. I reserve fillet-brazing to situations where there are no lugs available and where fabricating lugs may be possible but too expensive such as in tandem construction.

I feel that the process of building bicycles by hand with lugs has more in common with what fine instrument builders, saddle makers, and cabinet makers do than with what most bicycle companies do. As a craftsman and artist, I derive joy from working with my hands. Although I use powered tools and equipment, I prefer to use hand tools whenever possible. Some critics will no doubt scoff at this statement and jump to the conclusion that hand tools are too slow. But I have developed techniques and processes that are enjoyable, quick and quiet.

Next: Steel Bicycle Building Process