OCD Garage
100 W
I decided it was time for a new bike, this will be my sixth build, my forth with a custom frame. I wanted to build the entire bike this time, including the forks/handlebars as well. This will be my most ambitious build to date. Staying within a limited budget I opted for the Magic Pie 2, 24" x 65mm wide double wall rims, Kenda Kraze tires, 8" discs (which will be matching) with Avid BB7 calipers.

Central section of fork is done, used thrust bearings on either side of the main pivot. I devised a clamping system to attach my own bars.

Fork legs finished after a bit of weld clean up. As I don't have facility to do TIG I opted to ground things smooth.

The finished fork compared to the somewhat less beefy Schwinn style inspiration.

As the fork will have covered drop outs/pivots, I decided on a similar treatment for the rear. You can do a lot with an angle grinder, drill and files.

Mocking things for size/clearances in my uni-strut jig. It's not laser straight but really helps to keep things in alignment.

Forming the lower chain stays

First time sitting on it's wheels, mocking up the seat position.

Battery/controller rack built. To power the lights there's a mount for the DC-DC converter under the Controller. I've opted for a Greentime 3000 watt, 80 amp controller with a 48 volt, 30 amp/hr battery made from Samsung 18650 cells.

Here it's shown with second attempt seat mount as the first style didn't flow as I wanted. Discovered that my air shock was too dampened (non adjustable) so changed it out for a small coil spring style.


Central section of fork is done, used thrust bearings on either side of the main pivot. I devised a clamping system to attach my own bars.

Fork legs finished after a bit of weld clean up. As I don't have facility to do TIG I opted to ground things smooth.

The finished fork compared to the somewhat less beefy Schwinn style inspiration.

As the fork will have covered drop outs/pivots, I decided on a similar treatment for the rear. You can do a lot with an angle grinder, drill and files.

Mocking things for size/clearances in my uni-strut jig. It's not laser straight but really helps to keep things in alignment.

Forming the lower chain stays

First time sitting on it's wheels, mocking up the seat position.

Battery/controller rack built. To power the lights there's a mount for the DC-DC converter under the Controller. I've opted for a Greentime 3000 watt, 80 amp controller with a 48 volt, 30 amp/hr battery made from Samsung 18650 cells.

Here it's shown with second attempt seat mount as the first style didn't flow as I wanted. Discovered that my air shock was too dampened (non adjustable) so changed it out for a small coil spring style.
