Bike frame jig complete!

This easter has been jigtastic at work with another jig been produced during work hours and this jig produced in lunch times or in the friday afternoons that are always given off.

The jig was designed in solidworks and uses 6x1m aluminium 40mmx40mm profiles from a profile distributor (valuframe in this instance) including 4 angle kits (seen in Fig. 2) and 4 90 degree angle kits.

Fig. 1 - Complete jig

Fig. 2 - The flexible angle kit used

The tapered holders (which were chosen over steps so an infinite amount of tube diameters could be used) seen in Fig. 3, Fig. 4 and Fig. 5 were made from 2.5" aluminium bar that was machined on a lathe at a 50 degree angle to the central axis, then 3 of the four cones were threaded with an M8 thread to allow them to be attached to the angle kits (which also had to be opened up on the milling machine as I was unaware they were supplied for M6 bolts). The bottom bracket tapered holder has a 8.25mm hole through to allow the threaded bar to clear, two nuts are then tightened onto each other to allow a bottom bracket to be attached of varying widths.

Fig. 3 - Head tube tapered holders

Fig. 4 - Seat tube tapered holder

Fig. 5 - Bottom bracket tapered holder

The drop outs have a slot all the way through of 8mm to allow the M8 bolts to go through. This allows for a lot of alignment to be considered if anything doesn't quite go so well. The cones on either end are to centre the drop outs of varying sizes (which should happen with various iterators) which have a 8.25mm

Fig. 6 - Drop out holder with cones.

And there you have it, I have completed the frame jig in approximately 10 hours work in a work shop. All ready for the summer to carry on with the rest of the build.