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PB1 44

FORTYFOUR BIKE CO.

PROCESS BOOK for

The Lovely Do Everything Bike

PREPARED UNDER THE DIRECTION — OF — THE DEPARTMENT OF MAGNETISM

UNITED STATES FORTYFOUR PRINTING OFFICE NEW HAMPSHIRE : 2013 FOR FREE DISTRIBUTION BY THE SUPERINTENDENT OF DOCUMENTS, FORTYFOUR BIKES - USA

PG 04 05

FROM THE BUILDER RULE NO. 001 : SWEAR TO SHRED

www.44BIKES.com

I first got my taste of metal officially somewhere back in 1995 when learning jewelry and light metals under the tutelage of professor and mentor Leslie Leupe. Ever since that day there has not been a day when I did not look to have a torch in one hand and a file in another, pouring over the work of “legendary” builders of the craft. Fast forward to June 16, 2013 and I received an electronic communication from none other than Richard Sachs with the heading “YO KRIS -”. A pleasant surprise to say the least. What transpired is a collaboration between myself and Richard to build his wife Deb aka The Lovely Deb, a clean, modern tig welded bicycle capable of handling all conditions. A “Do Everything Bike”. Or DEB for short. Over the 40 hours of time I spent working on this bicycle, I have taken images of the process from start to finish. It’s with great pleasure that I have assembled them into this process book laid plain before you. Call it a record of process, methodology or homage to the craft that has been an ever beacon of inspiration. It is not intended to be a “how to guide” of constructing a bicycle frame. Enjoy and see you on the trail.

YO KRIS I wanna discuss having you bicycle. She’s a rider, but in using the old Rivendell Atla would like you to make a m like that - one suited for the basic position, and the sam drop handlebar setup, too. tom front rack on which the Maltese rides in. No fenders dated, and much less heavy

You up for a possible comm

u make my wife, Deb, a new recent years has settled into antis from the mid 1990s. I modern version of a bicycle e same wheel size, the same me basic wide gears. A non. No shocks. Maybe a cussmall bag that the 9 pound s. No lights. Just a nice, upy and cumbersome version.

mission?

PG 08 09

K. HENRY · NIKON D60 · All That’s Required.

PG 10 11

PG 12 13

K. HENRY 路 NIKON D60 路 Supporting the Top Tube.

PG 14 15

K. HENRY 路 NIKON D60 路 Fitting the Tubes.

PG 16 17

K. HENRY 路 NIKON D60 路 Internal Cable Routing.

PG 18 19

K. HENRY 路 NIKON D60 路 Finished internal Cable Routing.

PG 20 21

K. HENRY 路 NIKON D60 路 Slotting and Venting the seat Tube.

PG 22 23

K. HENRY 路 NIKON D60 路 Bending / Forming the Chainstays.

PG 24 25

K. HENRY 路 NIKON D60 路 Finished Chainstays.

PG 26 27

K. HENRY 路 NIKON D60 路 Tacking the Dropouts to the Chainstays.

PG 28 29

K. HENRY 路 NIKON D60 路 Chainstay Sub-Assembly Ready to be Mitered.

PG 30 31

K. HENRY 路 NIKON D60 路 Magnetism.

PG 32 33

K. HENRY 路 NIKON D60 路 Finished Chainstay Sub-assembly and Frame.

PG 34 35

K. HENRY 路 NIKON D60 路 Sequentially Tacking the Frame.

PG 36 37

K. HENRY 路 NIKON D60 路 Fully Tacked Bicycle Frame Cooling Before Removal.

PG 38 39

K. HENRY 路 NIKON D60 路 Bending, Mitering and Venting the Seat Stays.

PG 40 41

K. HENRY 路 NIKON D60 路 Welding.

PG 42 43

K. HENRY 路 NIKON D60 路 Head Tube Welds.

PG 44 45

K. HENRY 路 NIKON D60 路 Bottom Bracket Welds.

PG 46 47

K. HENRY 路 NIKON D60 路 Welding.

PG 48 49

K. HENRY 路 NIKON D60 路 Fully Welded Bicycle Frame.

PG 50 51

K. HENRY 路 NIKON D60 路 Prepping and Welding the ISO Disc Mount.

PG 52 53

K. HENRY 路 NIKON D60 路 Fitting and Brazing the Seat Stay Bridge.

PG 54 55

K. HENRY 路 NIKON D60 路 Finished and Ready for Paint.

PG 56 57

K. HENRY 路 NIKON D60 路 Paint by Circle A Cycles, Providence, RI.

PG 58 59

K. HENRY 路 NIKON D60 路 Paint by Circle A Cycles, Providence, RI.

PG 60 61

K. HENRY 路 NIKON D60 路 Paint by Circle A Cycles, Providence, RI.

PG 62 63

K. HENRY 路 NIKON D60 路 Paint by Circle A Cycles, Providence, RI.

PG 64 65

K. HENRY · NIKON D60 · TLD’s “Huntswoman” Complete.

PG 66 67

K. HENRY · NIKON D60 · TLD’s “Huntswoman” Complete.

PG 68 69

K. HENRY · NIKON D60 · TLD’s “Huntswoman” Complete.

PG 70 71

K. HENRY · NIKON D60 · TLD’s “Huntswoman” Complete - With Rack.

Be sure to...

ABOUT THIS PUBLICATION DESIGN DIRECTION K. HENRY

FONT FAMILY FUTURA

SWORN TO SHRED

POSTSCRIPT Special thanks to Richard and Deb for their consideration, patience and kindness for choosing me to be their choice of custom bicycle frame builder. It is with great honor and pleasure that I accepted Richard’s proposal to build his lovely wife a bicycle for all seasons and conditions. I look forward to hearing about all their adventures and travels with her new bicycle. Also thanks to all of my OEM accounts for making this bicycle possible including Henry James / True Temper for tubing, Paragon Machine Works for fittings, Chris and Crew at Circle A Cycles for Paint, ENVE Composites, Cane Creek, L.H. Thomson, Stan’s NoTubes, Quality Bicycle Products, and last but not least Jim and Garrett at Rev Limit Auto for their Powdercoat work. Without any of you, this project would not be possible and I look forward to many years of continued support for all of my bicycle needs.

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The Lovely Deb Process Book