Resizing a big bike

Got a smoking deal on a co-motion with a pinion belt drive. It was about the same price as the gearbox alone. I don’t really view a pinion as a performance drivetrain like a chain/ derailleur set up, but do think it’s perfect for adventure rides.
I set it up to still be pretty tall, handlebars about the same height as the saddle. Top tube length is about 6 cm longer than I usually run, but between the height, short tech bars, and a short stem I like the fit.

Since co-motion machined their headtube the od of the middle section was 45mm, not enough to ream and hold a headset, so I machined a cup for the headset cup. I also machined a plug for the non-drive seatstay to match the drive side. I was able to reuse the seatstays; the only new tube is the top tube. I am skeptical of the 28.6 od on the seat tube. If doesn’t appear that it was a butted tube, the factory clamp on the original was 28.6, so not externally butted. It’s still 27.2 where the new length ended up.

Next up is to make a custom frame bag. And cut down the steerer.

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That’s a genius approach to weld in the “new” top tube while the frame is still complete. For a second I thought that was going to stay a part of the design.

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