View Full Version : Phil's Highroller build thread!

09-20-2011, 11:59 PM
So I took the plunge yesterday and started my Highroller. I'm doing things a little different than the plans, but I think it will turn out ok. If not, I'll make it ok!
So I am using the seat stays and chainstays from my donor bike. I'm currently working on boxing in the chainstays where they meet the bottom bracket. I'm hoping that it will be strong enough once I am done. I'll be posting pictures of what I've done so far. This project will take me some time though, as I don't have any tools or resources at home, and this will all have to be done at work, either before work, during my lunch, or after work. So At most, I may have 2 hours a day to plan things out, and actually get any work done. I've already found out, that really isn't much time to do anything. As for me, well I work in a machine shop, and have full access to a mill, lathe, cnc and Tig welder.
Anyway, onto the pictures.

Here is the start of me boxing in the chainstays.

This is the second part of the boxing. I need to add another plate to the other side.

09-21-2011, 12:02 AM
another picture of the boxed chainstay.

Here is the headtube. I didn't like the way I ground off the other tubes, so I threw it on the lathe and smoothed it out. I also reduced the outside diameter so that I could drill a hole through the main boom with a drill bit I happen to have (1 5/16)

Here is the idler wheel I threw together quickly from a cart wheel I picked up for $1.00. The bearing and sleeve cost a whole lot more.

09-21-2011, 12:05 AM
next up is the bottom bracket. I really have to master the use of the grinder. Cause I really don't like the way I cut into the metal. I like the smooth look of a cylinder. I won't be able to chuck this up in the lathe.

09-21-2011, 05:17 AM
Outstanding work!
This is gonna be a thing of beauty! :)

*** The **** Is My Shepherd! ***
(Geezer & Bent Enthusiast At Large)

09-21-2011, 06:11 AM
Very pretty stuff. One caution - make sure you didn't take off too much metal on that head tube, or it may buckle on you under load. The general rule of thumb for short cylinders not to buckle easily is that the thickness of the tube should not be less than 1/50th the diameter of the tube.

09-21-2011, 07:16 AM
I'll be watching this. Keep the photos coming. :)

Radical Brad
09-21-2011, 10:44 AM
Nice build progress, keep it coming.


09-21-2011, 11:32 AM
Thank you for all the kind comments. I hope I don't dissapoint. But like I said, I've only got a few hours a day to do this, so it may be a little longer than most builds. But I do have a goal of trying to complete this before 10/30/11. There is a halloween bike ride I want to do!!!
As for my head tube, the O.D. is 1.307" slightly under the 1 5/16 I wanted, but I should still be able to get a good fit. The overall length is 3.350 and the wall thickness is right around 1/16". Do you think that is safe?

09-21-2011, 01:05 PM
I've got a quick question regarding the rear chainstays. Will my use of the donor bikes chainstays effect the 73 head angle called for in the plans? I wanted to weld them to the main boom so that they are in line and everything is parallel to the ground. Do I have to weld them at a different angle instead? I've been trying to visualize it, buy just can't seem to figure it out.

09-24-2011, 05:29 AM
I didnt make too much progress. But I did get something done. I went after the bottom bracket, and made my brackets. Here are a few picrures I took.

09-24-2011, 11:28 AM

09-24-2011, 01:25 PM
Your build and it it looking really good.
I think I need to pick up 1 of those angle finders!

09-28-2011, 11:41 AM
I finished welding up my bottom bracket assembly. I'm going to start working on attaching my rear "triangle" to the main boom. Hopefully from there I can gain some momentum, and get this project rolling!
I have to say I was a little dissapointed in my welding of the bottom bracket. I took time to make the gap as little as possilble between the tabs and the BB shell, hoping to not have to use filler rod, but in the end I still had to use filler. I don't think I cleaned all the oil/grease off the bottom bracket, so I couldn't get a good pool flowing. I am happy to say that I got no distortion and my cups thread in easily.

09-28-2011, 12:16 PM
Great Photo's Nice shop. Great work!

09-28-2011, 07:41 PM
Looking great there Phil!

I took time to make the gap as little as possilble between the tabs and the BB shell

with welding, it is actually preferable to have a small gap between your parts to allow the weld to penetrate deeper into the joint, also chamfering/mitre-ing the ends of the metal helps to get a stronger weld.


09-28-2011, 11:32 PM
Oh yeah. I forgot about the chamfering. I should have done that. Oh well, I know for next time. This is actually the first real project I have welded. I only learned how last month.

09-29-2011, 02:35 AM
You're doing great! :) Keep going, and keep the pics coming. :)

09-30-2011, 06:44 PM
got the "triangle" welded to the main boom!! almost got a roller. Just need to figure out where I'm going to put the head tube. What kind of wheelbase should I be expecting with this? I don't recall if it's listed anywhere in the instructions.
Anyway, here are some pictures. Oh, I do plan on boxing in the rear section. not sure if it even shows in the pictures, but I'm going to weld a plate in the back of the tubing so that it is boxed in and solid!

01-01-2012, 07:45 AM
Have you made any more progress on this project?

01-09-2012, 04:33 PM
Unfortunately not. Pretty sad to see it on my workstand too. I've just been too busy at work, then the holidays, and the cold weather (i have to work outside at home) But it's been pretty nice lately so I've been planning on getting this going again. I'll update again when this progresses.

01-09-2012, 08:21 PM
Take your time, what you are doing looks great so far.

01-21-2012, 01:12 PM
Yeah, take your time. :)

03-29-2012, 11:28 AM
Bump for an update. ;)