go we all rock hi I'm Paul Brodie and this is my shop welcome in these uncertain times
I thought that I would show you what goes on in my shop we've got a gator blade fork here
this was made back a long time ago in the 80s and it's got few break bosses on it and
the owner of the fork wants the candy bosses so we're going from obsolete to obsolete because
everybody's got a disparate now it seems so the first step is to get the bosses off
what I'm gonna do is to scrape off some paint because when I start to put heat on here when
there's paint I can't see what's going on so I need to do a little scraping exactly a little
hard to scrape off before this powder coat and powerto is harder than weapon now as I recall
on these break bosses these are silver so lid on so that means that it's kind of a low heat
so they should come off pretty easy we'll find out okay I have paper towels I have water what
I want to do is to stop a lot of heat going into the crown because I got to put heat on the bosses
and melt them off so what I'm gonna do paper towel and put it on the crown I'll take some
water I'll make it wet this a lot a little bit like a heatsink on the crown because I
don't want any unnecessary heat going into the crown because it'll affect the heat treating
get my neutral flame happening so what I want to do here on the boss is this is what most of
the heat on to the boss because I don't want to put any extra heat onto the tube you see
you see how I'm heating away from the crown is before on the flame it's pretty bright
it's kind of green that's because of the flux that's coming through the flame it's
part of my automatic flux ER so if I'm silver soldering or I'm brazing I've got flux on that
go
there you go okay this is the fixture which holds the braze ons and these are the new
cantilever bosses those go in there like that not sure if I got the right one on the right
side and that's the dummy axle it holds it holds the fixture in place so what happens
is this is holding these the brake bosses at the right distance off the axle because
the rim is a certain size if you get the brake bosses wrong then your brakes don't
work so I'm just making a couple marks so I know a way to scrape and sand and it's
the same thing again I just put my gloves on because this has got some sharp edges
so that didn't take a whole long time and you can see how all the Silva soul is gone it's nice and
smooth it just needs sanding now I haven't touched the crown it's good Emery cloth inch wide 80 grit
that's what I like is a crosshatch I'm standing one way and then I'm saying the other rows so
I'm getting a crosshatch like that and then as you Bray's over the top of that on a microscopic
level it's all uneven although to the finger it's smooth that's what the Bray's likes to grab on to
okay I'm happy with that here in the boxes is the cantilever Bray's on they don't get used
much anymore but some customers still want them so you have to have a certain amount of offset on
these Forks so that you get the spacing right and the spacing from Center to Center 75 millimeters
if it's if it's too wide the breaks fall down if it's too narrow the breaks are still coming up
it's important to get the spacing right let's go to the mill I want to tell you that it's an inch
hole saw because the size of the fork blade is an inch and I've offset it certain amount
545 now it's offset so when I go to do the other side I have to offset it 545 now the other side
so that's one side done I also want you to notice that on the whole so here it's at an
angle of seven degrees because that is the angle of the fork blade that
comes off in the future so I take out this and now I put it the other side like this
that's my zero right there and now I'm gonna go five hundred and forty-five style the other side
speaking of safety third what's first and second looking good going fast so
there she bosses and they be meited you can see how they're at an angle
of seven degrees and so what we need to do now is to take off the burner
I have a few little burrs on the inside I don't know if you can see that see little burrs so
I'll take this little round file I have a fixture here and this holds the candy bosses in place and
what I want to do is to check to see that I get everything right so if I move it a little bit if
I give it a little bit of wiggle I can I can check and see how how the boss is fit and it looks like
they fit pretty good I can't see any extra gaps around here so I say we're basically good to go
so what I'll do is I'll put a little bit of flux on there now you don't need a whole lot it just
wants to cover it what the flux does it protects the metal a little bit and it also helps the
braze in this case I'm going to use nickel silver nickel silver is a little bit stronger than the
bronze and it helps it to flow and what I'm going to do is I'm going to put a tack at the bottom on
one side and then I will nickel silver the other side if I just stop brazing one side sometimes
what happens is the fixture is gonna lift up and then and then your bosses aren't lined up anymore
adding some oxygen if you can hear that now there's a hiss that's an indication
that it's a little bit too big so I'm closing down the oxygen and try that
I'm gonna tack one side so it doesn't move raise up when I do the other side
music text
it's part of being a fussy fan game which is a hashtag I'm going to the
next okay so one size done we'll go back to the first side that ikat
and that's it so when I pull off the chair there on
I'm gonna show you here how to align a fork I made all these all these fixes well I didn't
make the candy pills but I need other things lots of holes this is back in 85 when every
friend every frame bill that was making Forks what this one does it shows you how the fork is aligned
as compared with the with the steer tube so the axle is 100 millimeters so the spacing needs to
be a hundred and one millimeters it's next two millimeters so that it always slides over the
axle if I measure this you can see that it's 98.5 so I need to pull this out a couple millimeters
and this was designed so that this shelf is at the right height and I can put my knee here and
then I can give her a little bit of force and I just want to pull it a little bit I'm lining a
friend before this is what I used to tell my class it's the two F's its force and finesse and maybe
it seems like like like they don't go hand in hand but need force to pull but you need a little bit
of finesse Oh a lot of finesse as well because you pull a little bit and if it doesn't go away
well we're at 100.3 I don't want to pull more than that so I'm gonna see that's good so that's the
first stage of alignment and getting the forks of it on the dropouts they are equidistant in
the center line and what I've got here is just a piece of alloy put that on the fork blades you
eyeball from this level to here and that tells you if the forks have any sort of an epic twist
okay so this side is a little bit higher so I can either pull the right side back or pull the
left side forward so maybe I'll do a little bit of both so I'm coming back on this one
okay well I'm going to call that good now what we have to make sure is that each leg is the
same distance from the crown so that's what this fixture does put it in here and it's a
little wider than 100 millimeters you see how it's equidistant on each side and then if you
if you want to double-check the fixture you take this off and you put it on the other way
this is how you know if you fix just good and the fixture is good because it's right in the middle
so that fork is basically aligned thanks for watching I appreciate that maybe you'll want more
you