Haha. I tweaked it enough you can’t be held accountable 
I didn’t buy the brakes, the customer did. Took him three drops before he won the internet lottery 
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Cheers. Not a fan of low BB I find them awkward to change direction. It’s counter intuitive in a way but I don’t look at it as from the ground but from the axle. So running the modern geometry that is longer it helps keep the platform stable in the front to rear pitch but still change directiona bit easier.
The client is 6’4” with long arms but a tight neck so a little more upright as well.
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If that does not work out for him it will fit me perfectly. Love the design. 32” for the win!
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Hi Sean,
I’m very curious about the tube set you will use.
-Thom
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35 x 0.9 4130 tube for top and seat. Formed/folded down tube from 0.9mm 4130 sheet in two pieces. Columbus disc fork blades for the seat stays and shaped 22 x 0.9 4130 tube for the chain stays
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Cailte DH evolution…
I’ve gone over and refined a few things from the original that needed work. The same awesome confidence inspiring geomtery and suspension layout. Have not found a need to tweak anything there.
- Deleted the needle bearings for deep groove ball bearings which meant linkage architecture had to change.
- Improved hardware design.
- New seat post tower, cleaner lines and architecture using a 31.6 seat post and integrated clamp.
- New swingarm with nicer lines and some clearance to the chain which will allow space for a nice thick chain slap protector.
- More tyre clearance at the swingarm and seat stay which meant new seat stay bridge and swing links.
- New replaceable drop outs. These will aloow different chain stay lengths for rider preference.
- Revised Horst link pivot hardware with off the shelf items.
- New 3D printed head tube (previously just fillet brazed tubing) This makes for a stronger unit with stress reducing wall shapes and surface blending.
- New two part cable guides that require less tube fabrication and keep the housingoff the paint surface. Allows easier cleaning of mud and prevents scratching the paint.
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Hey, I’ve been admiring your work and wanted to post myself too. Are you considering soldering or tig-welding the E-bike? I’m assuming these are the lugs for the E-bike you showcased earlier. Really can not wait to see more details regarding this build. Maxon? Hope to talk to you soon as I am keen on trying 3D printed steel myself too. Cheers!
Hey mate, these will be TIG welded. I am moving all teh mtb’s to welded construction and leave teh fillet brazing for the tube to tube joints on the road and gravel bikes
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is that Honeycomb matrix inside the BB shell to help keep it round when printing? Am I completely mistaken about this being a printed part?
@DEVLINCC I love your bikes and style. I’m a fellow Aussie on the west coast just getting my feet wet with some frame building / bodging projects. I was wondering what local brazing rods and fluxes you have used in the past for mild steel fillet brazing? I see you’ve moved away from fillet brazing and gone to TIG but as a long time refrig mechanic brazing comes naturally to me so I’m starting with that first.
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For manganese bronze I use the BOC 1.6mm rods and I have a stash of Cycle Design bronze flux. Niche Gas in Melbourne does the gasflux for that. Silver I get from Hampdon in Perth. They have both 56 and 45 in cad free. I just use the Tradeflame silver flux from Bunnings though it’s a bit finicky, not as nice as the Cycle Design
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Yes, though just using a cross brace now and printing with some green to machine or file back
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Thanks for the info, Hampdons are not far from me and I’ve been using their prefluxed manganese bronze but recently had to rebraze a downtube in to a BB shell so bought some of the CA 303 Flux to pre flux the tube but it didn’t really like being mixed up as a paste. Looks like I should get some of the Gasflux Type B from Niche. For silver I’m lucky to have accumulated a heap of shorts of SBA245 in my toolbox over the years as a fridgy so have enough for a few years of hobbyist tinkering, I can’t believe the price of silver these days 
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Yeah I had a stroke when I ordered the last lot of silver a couple months ago. 10 sticks each of 56 and 45 cost me $1000!!! One of the reasons I am moving over to TIG as the 3D printed parts being stainless won’t take the bronze. Just spent nearly $3k buying the welder and welding table. I could have not bought the table but I could afford it at the time and will look good in the new space. I might not make any money building bikes but I have a nice workshop!!
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3D printed parts arrived earlier than expected. Had them glass bead finished. Forgot to order the brake mount though 
not sure how I’ll rectify that in time for Sea Otter Australia.
Last of set up for the time being in the new workshop. Need to shift the mill and alignment table after Sea Otter
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Really jealous of the workshop and the parts look amazing. Hopefully you have time to post manufacturing and ride details here. I’m interested in the concept and hope the best for the project.
I will try and get fabrication shots. My phone is virtually a potato at the moment so need to find a better image collector. 
Hopefully I can ride it before sticking it in the van for the big drive to the show. If this goes well building it I will start on the 32 XC dual susp. and see if I can get that frame ready as well. Unlikely though.
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First dry fit up of the front end. Still need to make a motor delete bracket and get everything neat before any welding. Had a mate make the down tube. Clam shelled in two halves. It was a fraction too wide so have had to split it and will fit it up tight. Everything else working well so far.
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Another sick build. Well done sir
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