I am designing and building a bonded aluminum high pivot enduro frame, but don’t exactly know how to build my own jig for the assembly or what I need to build it. If anybody has built a full suspension front triangle id like to hear about it. The rear triangle and lugs are going to be entirely CNC machined, but If I have all the aluminum tubing for the front triangle, what is the best design to correctly mate the lugs and the tubes? I have seen Neko’s Bonded DH frame and am wondering how easy it is to create that same bonding interface where the tubing and lugs meet. Also, what bonding agent is recommended for a project like this. Thanks.
3d printer and a sheet of MDF. Print blocks to hold the key parts in place that bolt down the the MDF sheet to hold them in place. Don’t over think it.
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You could print little locating spigots where the slip joint is. File/machine corresponding slots in the tube and you have no need for a jig for the front end.
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This is how I bonded my front triangle and in my opinion this is about the minimum viable option. The seat tube and head tube are located on printed blocks. Seat tube is rigid and positioned on the CNC table with pockets that i machined into the MDF blocks to locate the printed parts.
The print for the head tube also has a pocket, but which is open in the front so the whole assembly can be slid together with only one degree of freedom.
If you have round tubes you probably need another rest for the down tube to correctly clock the bottle bosses.
I did everything on the CNC table as this is the flattest surface i have, but no reason you can’t do this on any other surface and with some measuring.
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