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Dazza
07-07-2016, 10:19 PM
COLOR="#0000FF"]the most beautiful tool (well worn 30 year old lathe) meets lump of 304 stainless, for Columbus Bio conical seat stays[/COLOR]

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Dazza
07-07-2016, 10:26 PM
Braze, file, sand and sand and sand and
and and and sand and sand and
then polish

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The shorelines reflect the dropouts, that is the intention

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Dazza
07-07-2016, 10:33 PM
No chrome here, never chrome

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Dazza
07-07-2016, 10:58 PM
little work

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8aaron8
07-07-2016, 11:41 PM
My fingers are aching

Llewellyn
07-08-2016, 06:07 AM
Wow, just wow.

Wondering if I can squeeze another one in the bike room :banana:

staggerwing
07-08-2016, 07:29 AM
Having made and polished a few stainless bits over the years, I realize that is an absolutely sick amount of work to get to that point. And, you can't cheat with machine polishing, save for the final high polish, or else all the beautiful lines get blown.

Outstanding.

DreaminJohn
07-08-2016, 11:47 AM
Awesome, beautiful, heavenly.


I am humbled by your skills.

Please don't ever stop posting stuff like this.

Dazza
07-08-2016, 06:38 PM
Wow, just wow.

Wondering if I can squeeze another one in the bike room :banana:

Of course you can :cool:

Dazza
07-28-2016, 09:09 PM
I have had some frame lug project ideas rattling about in my cranium for over 12 years, then at the recent UK Bristol Bespoke show in April I had many conversations with my established frame building peers over many a splendid evening dinner along with few fine real ales :-). Their enthusiasm for these possible projects stimulated me to make some movement, so on return to the world wide head quarters of Llewellyn Custom Bicycles in sunny Queensland I was motivated to get busy and bring these projects to fruition. The 3D CAD was fired up on the Dell and for several plus weeks I worked, studied and experimented on developing a new surface technique for the vision of these 3D models. This new technique was formed which gave more scope and refinement in the model's design but technically detailed and tricky, but pleasing. It is a case of a 100 hours to work out how to do it and then only 8 hours to do the final model. The next step was the 3D prototypes printed by acquaintances to look over and tweak the shore line aesthetics. When the tweaks were done, it was press the green go button for the tool maker to create the wax shooting moulds for the investment casting process at the foundry. These new tools are being made at this time and in some weeks time the first samples will arrive.
Stay tuned for new Crescendo and Cadenzia socket seat stay lugs to fit Columbus tubes later this year.
Next is new sweet looking BB shells and fork crowns with a soft flow to them and easy to use, however I have much on my plate outside of bikes so I have no idea when.


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cadence90
07-29-2016, 12:46 AM
.... ..
.

DreaminJohn
07-29-2016, 10:39 AM
Busy outside of bikes??!! How dare you. ;)

Beautiful work. Truly.

Dazza
08-01-2016, 11:18 PM
Cadenzia lug set, Humm?, whizz, drill, whrrr file file


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Dazza
08-01-2016, 11:24 PM
after the first cup of tea this morning

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then after the second cup of tea

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Dazza
08-01-2016, 11:27 PM
After 5 hours, the three some is ready for hooking up, but now it is lunch time

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Cicli
08-02-2016, 06:09 AM
Beautiful.
And all before lunch.

Stunning work.

Dazza
08-02-2016, 02:44 PM
Beautiful.
And all before lunch.

Stunning work.

Yep, started at around 6.30-7.00, finished just before lunch at 12.00. Did the playing cards and reworked the shorelines on the three lugs with the high cut on the top tube lug to reveal more head tube.
Lunch raw salad, interruptions and stuff and back to the bench brazing drops to chainstays.
I knocked off at 6.00pm

weisan
08-02-2016, 06:22 PM
Simply exquisite.

https://cdn.vectorstock.com/i/composite/13,35/royal-crown-vector-1301335.jpg

Dazza
10-05-2016, 12:06 AM
A stainless badge is cut by "light amplification by stimulated emission of radiation"
a bit of filing via the jeweller’s files, some pressing with formers
cook up with 56% silver rod fed in

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File sand and polish then some Joey paint magic
Dazza gets his special shaped blade to break the edges of the masking/paint

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A touch up polish with the little felts and the special green rouge

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to Dazza's tragic mind, it seems to be the genuine way to do the head tube logo,
so it has to be

Dazza
10-05-2016, 12:22 AM
If you are passing by Covent Garden London some time soon, call in to the B1866 store to pass your eyes and fingers over a Llewellyn "Voyageur" randonneur machine. It can be yours

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Dazza
10-05-2016, 12:31 AM
if you are kicking about the ether
got a glass of your favourite red or ale in the hand
poke here
http://www.bespoked.cc/Features%20Pages/llewellyncustomb.html

Llewellyn
10-05-2016, 08:26 AM
if you are kicking about the ether
got a glass of your favourite red or ale in the hand
poke here
http://www.bespoked.cc/Features%20Pages/llewellyncustomb.html


Great interview Dazza :beer:

Dazza
10-13-2016, 04:09 PM
I am enjoying Heather's build, lots of work and the results will be sweet for her.

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Dazza
10-13-2016, 04:33 PM
Great interview Dazza :beer:

Thanks, it was fun with Poppy and the Bristol mob are good fun. I am going back next April is the stars and planets align and the tea leaves are favourable

8aaron8
10-13-2016, 11:43 PM
Killer details as usual.

Dazza
10-18-2016, 07:04 AM
a wee bit of
contemplation

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Dazza
10-18-2016, 07:12 AM
first sample arrives, bench time ..................

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you will have to be patient, production lugs will be 2-3 months away

mwynne
10-18-2016, 08:22 AM
Ooh yes that is a devastatingly attractive seat cluster

Sent from my Nexus 5X using Tapatalk

timto
10-18-2016, 04:11 PM
Seat lug looks superb! Excited to try a set.

Dazza
10-23-2016, 08:20 PM
Cook up a file
Very pleased with the result. The time spent with the 3D CAD and test assemblies ensured a full score.

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cadence90
10-23-2016, 11:33 PM
.... ..
.

weisan
10-26-2016, 08:49 AM
Well done well done.
It's satisfying when everything came together at the end.

Dazza
11-18-2016, 08:24 PM
No chrome was harmed in this production, Paul's Cadenzia is off to Melbourne

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merckx
11-18-2016, 08:41 PM
^^^^^^^
Like

8aaron8
11-19-2016, 10:28 AM
Gorgeous bike, Mr. Cosgrove does amazing paint work, and you, of course, build amazing frames.

soulspinner
11-19-2016, 01:53 PM
Just shaking my head again. Beautiful bike. Love that secondary color.

Dazza
11-21-2016, 02:25 PM
Gorgeous bike, Mr. Cosgrove does amazing paint work, and you, of course, build amazing frames.

Yes, Joe Cosgrove does do good paint job.
He is not a very public person however he has dedicated his life to bicycles.
It has taken 27 years of collaboration to this point.

weisan
11-25-2016, 06:12 AM
Paul's Cadenzia is off to Melbourne



I have fond memories of Melbourne. Hopefully Paul, the new owner, can bring the Cadenzia to the tip of the peninsular for a visit and take some awesome pictures to share...

Pt Nepean National Park, Sorrento

http://alicehui.com/AUS/pics/mini-P1120200.JPG

Arthurs Seat, Port Phillip Bay

http://alicehui.com/AUS/pics/mini-P1120382.JPG

Dazza
11-25-2016, 09:40 PM
Onto the stainless steel racks now

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to fit Zefal HPX pump, properly

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Dazza
11-30-2016, 03:31 PM
Stainless tube meets the marvellous "Carol" the magnificent tube bender

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neby2016
12-06-2016, 02:26 PM
Jaw on floor. All of those pieces are incredible. Now have to select one or two for a computer wallpaper!

Well done Sir!

cadence90
12-06-2016, 03:48 PM
.... ..
.

bironi
12-08-2016, 06:30 PM
Very elegant rack.

bob heinatz
12-16-2016, 03:02 PM
Soon Dazza soon!

Dazza
02-03-2017, 03:47 PM
Heat guns, soldering irons, and every thing else is on the bike assembly bench in the bike assembly room.


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John's Rando is being assembled

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Dazza
02-07-2017, 03:39 PM
John is going on adventures

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Dazza
02-21-2017, 05:11 PM
Neil's Llewellyn Cadeniza machine equipped with Dura-Ace 9100 and Dazza built wheels. A blend of Italian, Japan, Swiss, USA, UK, Taiwan, France mixed with some Aussie hand powered toil.

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superbowlpats
02-22-2017, 09:16 AM
That blue is exquisite :hello: as with all of your work, just magnificent :beer:

Dazza
03-16-2017, 05:25 PM
Ponder

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WHIZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZZ ZZZZZ

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Done

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soulspinner
03-16-2017, 06:24 PM
:hello::hello::hello::beer:

Dazza
03-27-2017, 04:17 PM
off to my favourite bike show soon, 'Bespoked"
Getting stuff ready.

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Dazza
03-27-2017, 05:20 PM
28th March Brisbane – Australia. Llewellyn Custom Bicycles announces two new socketed seatstay seat lugs, one each for the Llewellyn Crescendo and Cadenzia lug sets. Darrell Llewellyn McCulloch, designer of the lugs explains; “These seat lugs are created to expand the versatility of the two sets. This lug provides different aesthetics and working methods than the original seat lugs of each set.” Sample lugs and Llewellyn frames built with these lugs will be on display at the "Bespoked" show 7th-9th April Bristol UK.

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notfast
03-30-2017, 11:31 PM
This whole thread is amazing. Keep up the amazing work, Dazza.

cadence90
03-30-2017, 11:35 PM
.... ..
.

Dazza
03-31-2017, 05:03 PM
It is about what I do, it is about making, it is about bicycles and this particular flavour,

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Dazza
03-31-2017, 05:07 PM
it is where the cool kids hang out and the nerds hang out and lost souls from down under

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Llewellyn
03-31-2017, 07:17 PM
That tying and soldering is so cool that I'd love to get it on a set of wheels even if it doesn't provide any tangible benefit :hello: Enjoy Bespoked Dazza

roguedog
04-16-2017, 09:21 AM
Looking good out there, Dazza. Saw this vid: https://youtu.be/sq62zWqn8hA

Some nifty work on the rack and bag set up. That musta been a fun project. Is it now an add-on to your offerings or was it just a one-off?

Dazza
04-25-2017, 04:24 PM
Looking good out there, Dazza. Saw this vid: https://youtu.be/sq62zWqn8hA

Some nifty work on the rack and bag set up. That musta been a fun project. Is it now an add-on to your offerings or was it just a one-off?

These are a standard offering on my bespoke stainless steel rando racks with Gilles Berthoud bags. All my workshop stuff is for production.

https://www.flickr.com/photos/llewellyncustombicycles/albums/72157650147033787

Dazza
04-25-2017, 04:25 PM
Just back from "Bespoked" (Bristol UK) after a few weeks holiday time after the gig. A few pics here of setting up in Brunel's Passenger Shed. Big thanks to Robin Mather for making the display stand for "Wayne's Obsession" and his hard work assisting in setting up.(that is Robin up the ladder) Also a big thanks to Mark Stanley for his assistance. They made it so much easier for MAM and myself after stepping off the airport shuttle bus, straight in the door of the venue to set up the stand before we even checked into our hotel digs the evening before the show kick off.

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Dazza
04-25-2017, 04:41 PM
One most enjoyable aspects of attending "Bespoked" is the evening dinners with fellow toiling frame builders. The banter and knowledge shared is fun and for me I only get to do this once or twice a year, so it is special. It all goes too quick, just too quick !

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Dazza
04-25-2017, 04:59 PM
One special dinner MAM and I had after Bespoked was done and dusted was on the Monday evening with Robin Mather and Vincent Crétin. Vincent Crétin is a young man who I knew of but knew little of. However as we all chatted for many hours that evening he made an impression on me because he is following his vision of needing to be on the path to be a complete "Constructeur". He moved to commence work at Gilles Berthoud (France) to follow this vision. He is not taking the easy path, he is not taking the short path. He is not about fluff and bright funky colours. This young man is a genuine frame builder. I will enjoy growing old following his work.

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Dazza
04-25-2017, 05:41 PM
I felt very emotional about this award. Because it was not for the best looking Sunflower on a townie bike's wicker basket with nice colour path ways, this Blue was judged by some very experienced life time frame builders. Yeah, I teared up a wee bit.

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pncguy
04-26-2017, 04:56 PM
Stunning. Congratulations on the award.

Hilltopperny
04-26-2017, 07:26 PM
Congratulations Dazza! A well deserved award for an amazing machine:beer:

shinomaster
04-29-2017, 12:53 AM
That's an absolutely gorgeous bike! :beer::beer::beer::beer::banana::banana::banana::b anana::banana::banana:

Dazza
05-10-2017, 05:09 PM
Scott's Colossus frame forms up

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cadence90
05-10-2017, 05:30 PM
.... ..
.

Dazza
05-11-2017, 05:31 PM
Circa 1978. I lived for my manual training classes of metal work, wood work, tech drawing and running at High School. My manual training teacher had been involved with bike racing so we got on well as I was dreaming of being another Eddy. For some forgotten reason I needed to use a divider for a project at home. My teacher said, "take these" I will bring them back on Monday. He said, "keep them, you will make good use of them" Nearly 40 years later I reflect on the story of these Moore and Wright dividers that have lived on the back of my bench. They have been used on every Llewellyn frame set I have made. Did I make good use of them?

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Dazza
05-11-2017, 05:34 PM
Wow, that will be a great looking frame.

What are the ODs on those tubes?


All in here some where
http://forums.thepaceline.net/showthread.php?t=181997

cadence90
05-11-2017, 06:55 PM
.... ..
.

8352
05-15-2017, 08:27 PM
Reminds me of silversmithing jewelry. Insanely technical work, very satisfying to see work is progress pictures!

Dazza
06-01-2017, 05:20 PM
Scott's Colossus makes progress

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Dazza
06-01-2017, 05:22 PM
Building bridges

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Dazza
06-01-2017, 05:26 PM
The "Little Nipper" M5 binder bosses

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Dazza
06-01-2017, 05:36 PM
The Little Fella DT M5 Boss. Totally Stainless.

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Dazza
06-01-2017, 05:37 PM
Colossus is ready for Joey's lick of colour

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merckx
06-01-2017, 05:57 PM
Like^^^^^^^^!!!!!!!!

soulspinner
06-02-2017, 05:18 AM
Chapeau Dazza!:beer:

Dazza
06-19-2017, 07:56 PM
They need a good home. They need to be ridden. I need the space and room for projects. Twist my arm. The phones are manned 24/7 at the world wide headquarters of Llewellyn Custom Bicycles for the end of financial year sell out make room bargains Exit 61 (0) 7 3353 3368
More here
http://www.llewellynbikes.com/blog/wordpress/

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and
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and
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and
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makoti
06-19-2017, 10:09 PM
Dear Lord, that white bike is gorgeous! I'm going to shoot you an email... questions...

Llewellyn
06-19-2017, 10:40 PM
Dear Lord, that white bike is gorgeous! I'm going to shoot you an email... questions...

These are great deals. I could probably make either that fixie or the candy apple and white one work for me, but alas I doubt that I could get either one past the CEO review process :crap:

Dazza
06-22-2017, 04:05 PM
It is a well known fact that Llewellyns enjoy a trip to the sea side
There has been a sighting at Malibu beach

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beeatnik
06-23-2017, 10:34 AM
weight weenie Llewellyn is mad!

Dazza
06-26-2017, 03:36 PM
weight weenie Llewellyn is mad!

blows their hair back

Dazza
07-02-2017, 06:53 PM
If you are rolling through London, call into the Rapha store and go home with your Llewellyn "Voyageur" .

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Dazza
08-21-2017, 04:08 PM
27 years on and I am still doing MAX forks. Good stuff.

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Whirl whizzz whirl file file sand

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Cook up

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Dazza
08-22-2017, 04:35 PM
Noel's stainless steel crown gets some treatment. My crown work is cheaper than my dentist.

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Dazza
08-23-2017, 06:33 PM
Adding details to Noel's bottle boss reinforcements

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dave thompson
08-23-2017, 07:29 PM
Details, details. Lovely.

Dazza
08-28-2017, 09:34 PM
Scott's Llewellyn "Colossus" emerges from the chrysalis to meet the Queensland Sunshine for first time.

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m4rk540
08-29-2017, 01:56 AM
Purity of purpose. Bravo.

Could we see close ups of the headtube? I feel as if I'm seeing the same chromed tab/paint protector which is on the seat tube.

Edit: Just took a look at the headtube in the process photos. Thoughtful, lovely details.

Dazza
08-30-2017, 04:03 PM
Purity of purpose. Bravo.

Could we see close ups of the headtube? I feel as if I'm seeing the same chromed tab/paint protector which is on the seat tube.

Edit: Just took a look at the headtube in the process photos. Thoughtful, lovely details.

No chrome, never chrome here since 1997. Only stainless steel for the shiny bits.

Dazza
09-19-2017, 05:56 PM
Back to Geoff's Lucentezza Custodian frame set that will have a few twists.

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one lug is done, one lug left to receive the toil

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Dazza
09-19-2017, 06:12 PM
Geoff’s new LLeweLLyn is a variation of the Colossus frame set, using Dedaccia formed chainstays and seat stays, fitted up with SRAM eTap. A mix of Columbus and Dedaccia tubes are fillet brazed with 55% silver content brazing rods, stainless steel fittings. Joey did his Candy Apple Red magic and voila.

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Dazza
09-20-2017, 04:14 PM
Making bikes, simply make bikes, just make the bikes.

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Dazza
10-14-2017, 04:19 PM
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The Joker is ?

jtakeda
10-14-2017, 04:22 PM
The cable rub notch is genius. Thanks for all th pics

Dazza
10-14-2017, 04:25 PM
A lathe is a beautiful thing, then is is hack hack gring grind , whrrrrrr whizzzz, whirrrr, file file file

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Dazza
10-14-2017, 04:33 PM
Cook up

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I could
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Hand mitre in

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the easy path would be just to write poetry about my self but as Nick Cave tells us

"Most people wait for the muse to turn up. That’s terribly unreliable. I have to sit down and pursue the muse by attempting to work."
Nick Cave

Dazza
10-14-2017, 04:38 PM
Insert significant toil to stainless steel

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cadence90
10-14-2017, 04:41 PM
.... ..
.

Dazza
10-14-2017, 07:24 PM
Wow.

We would all be so lucky as to have even half as much fun and joy in doing our daily work as Dazza clearly does in his.
.
.

The enjoyment for me is to go there once, to take one's creative needs to a place, just once and then having done it, move on, but to repeat this again, the reality is that the price is rising to balance the price of hours and the strain. So if some one must have a frame, fork, stem and spacer like this "Llewellyn Lucentezza" frame set, it is now $12,500 aud. It has to be such.

The bikes have been good to me, I do enjoy my work, most of the time, but my mind is exhausted after 38 years since I started work at Hoffy Cycles in Sandgate. I feel like I am at the end of my energies. I feel I am coming to the end of my time doing this high polish stainless work, so as to be rid of the incredible implications that is demands. It takes so much time, it takes so much out of my mind and body. I am in no way exaggerating the toll it sucks out of my mind and spirit. It has been now over 17 years of doing these and it's worth to me has diminished, in respect to both fiscal and emotional . If any one wants a Llewellyn Lucentezza from my hands, then 2018 may, just may be be the last year I will let myself inflict such flagellation. But as with many things, time passed diminishes the memory of the toil and some one comes along and twists my arm.......... and it starts all over again......................

Vientomas
10-14-2017, 07:53 PM
Your craftsmanship is astounding. I shake my head in disbelief when I view the images of your work. Simply amazing. Thank you for sharing your creative process with us here on the forum.

cadence90
10-14-2017, 07:54 PM
.... ..
.

Dazza
10-18-2017, 04:51 PM
Rub rub rub ......................................rub rub rub...................................... ache ........................beer, aghhhhh.

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weisan
10-19-2017, 05:27 AM
Labor of love.

Dazza
10-19-2017, 05:02 PM
This crown has been Dazza'ed

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I am pleased with the out come of the curves

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It is not about me, it is about the bikes I can make for ya

"Most people wait for the muse to turn up. That’s terribly unreliable. I have to sit down and pursue the muse by attempting to work."

Nick Cave

https://www.youtube.com/watch?v=1GWsdqCYvgw

Dazza
11-22-2017, 05:01 PM
Why do I design and produce frame castings and parts for steel frame construction?

There is a fair quantity of frame fittings and lugs on the market for a frame builder to choose from, much of it is from the 80’s and early 90’s era when steel frame production was ubiquitous. It is a pile of toil and expense to design and produce new casting designs, so why do it?
During my normal daily work at the bench making frames I found those 80’s and 90’s frame parts and some more recent designs lacking in many ways, they:
• do not exist for particular frame geometry, thus restricting design considerations.
• do not allow the builder to modify them for aesthetic or design considerations.
• didn’t exist for larger tube sizes which are better suited for use in frames for the larger and or heavier rider.
• are missing important design features that belong in 21 st Century lugged steel frame construction.
• are time costly and difficult to use correctly or to modify for design considerations.

Right from the start and to this day I do not design and produce new parts to exploit a perceived demand in the frame builder’s market, but firstly only to fill a need I have in the Llewellyn workshop production. However the initial design, tooling and production costs for new frame fittings are considerable and my own in-house production volume would never recoup these costs. To recoup the considerable expenditure I sell these Llewellyn parts directly to other builders or via my agents in the USA and Europe.
I will start with an out-line of the investment casting process and then follow a chronological order discussion of the Llewellyn parts I have created and give a short rational of the “whys” of their creation and some of their features:

• “Llewellyn Stem lug set” – First stem lug set for 1” and 1 1/8” forks and 31.8 handlebars.
• “Crescendo” lug set – World’s first road frame specific sloping top tube lug set for XL (DOS) tubes.
• 30.60mm seat posts that fit directly into 0.50mm wall 31.7 seat tubes
• “Little fella” Gear boss – Stainless Steel investment cast threaded M5 DT gear cable boss, for 31.7 and 35mm down tubes.
• Manorina –A road frame specific sloping top tube lug set for OS tubes
• Track Dropouts – Track dropouts with enough material for placing on larger stays
• Dropouts – Investment cast dropouts with and without twin M5 threaded eyelets
• Limpets – Stainless gear and brake cable bosses
• Custodian – Level top tube lugset for OS tubes
• Cadenzia – Level top tube lugset for XL tubes in partnership with Dario Pegoretti.
• Rack bosses
• Nipper M5 seat tube binder boss. For lugless frame construction.
• XLH-4 Socket stay seat lug Cadenzia – Level top tube lugset for XL (DOS) size tubes.
• XLS-04 “Crescendo” Socket stay seat lug – sloping top tube lugset for XL (DOS) size tubes.
• Project underway, new process for casting, custom designs and a new frame set with lugs and fittings for mega tube size. Why, because I get asked for this.
• Projects in the wind, decent fork crowns that ease the builders toil and work well and look sweet
• Project in the wind, decent BB shell that ease the builders toil and work well and look sweet with correct angles.
• Socket seat lug for Custodian and Manorina lugs sets (OS tube size)

Please feel free to ask if you have any questions. If you want some of these goodies, you know where to find me 😉

Dazza
11-22-2017, 05:06 PM
Part One.
The Llewellyn Casting design story.
I stated working at age 16 Hoffy Cycles October 1979 for the owner Eric Hendren, I went there because I wanted to be a frame builder of custom bicycles. (the “why” is another story) At that age my 16 yo rose tinted glasses were very bright. Eric was using mostly pressed lugs and BB shells from his stock of Tange parts he had stashed in large tins in any corner that was convenient on the floor. This stash was a result of a trip to Japan he won via the bicycle trade. Around this time investment cast BB shells and lugs were starting to make their presence, mostly Cinelli if I recall. I was infatuated with all things concerning frame building and hand-made steel frames was ubiquitous in the quality cycle world. It was long before the corporations would arrive, we had no idea of what was to come, we lived for the time, rode bikes, trained and went racing and spent our scarce wages on bikes, travel, hotels and racing.
The picture is of me holding a Tange BB shell, that if you look closely you can see it is Blued for marking out and I had cut a playing card in the DT socket and most likely it had a H on the bottom of the shell. I would take the lugs home in my back pockets and would drill and file in a corner of bedroom. Why in my bedroom, because mother was very ill and it was the only safe space to do this and I was not allowed to set up a table with my little vice in the garage. I would get $15.00 for a set (enough to buy a training tyre) and Eric would use them on the Hoffy frames when the customer requested this detail. In the pic below Eric is actually repairing a striped thread in the BB shell of a 3 speed roadster. We fixed normal stuff and got it out the door and back on the road. Can you imagine shops doing that now? Unless they can throw it away and order the new part on line and then bolt it on with a “torque wrench” and so claim they are clever bicycle technicians while you wave your CC card over their machine, they are effing stumped ! You can also see some Reynolds tubing boxes on the shelf. On the other side of corridor beside the shop was the hairdressers and a couple of very nice young lasses worked there. It was absolute torture/frustration for me as they walked past the big sliding doors next the work benches to the lunch bar.

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Workshop Hoffy Cycles Sandgate Brisbane circa 1984. Darrell McCulloch and owner Eric Hendren.

Dazza
11-22-2017, 05:18 PM
Part Two The Llewellyn Casting design story.
In Queensland it seemed we lived in isolation from the world of frame building. It was out there somewhere but what was out there seemed bigger, brighter and more glamorous than Brisbane according to the bike magazines. If you went to the summer track carnivals you would see 75% of the bikes being ridden were from Hoffy, if you went to the winter road races you would see 50% of the riders astride a Hoffy, all made by Eric in Sandgate. We saw some frames from interstate and the occasional imported Italian frame set but it was Hoffy frames everywhere. Keep in mind the race scene was all there was, very little cycling was done as a recreational past time back then. The adverts for investment cast frame lugs and parts were appearing in the pages of cycling magazines and I would over scrutinise any picture of frame making or a workshop that appeared on the pages. One particular book that I absorbed at the time and was a huge motivation was “The Custom Bicycle”. Wow, I thought. ......... Meanwhile Eric kept whistling to the tunes on 4BH radio and I longed to listen to the test cricket on the radio while Suzy and Tania kept walking past on the corridor beside the bike shop to the sandwich bar. Sigh!

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Dazza
11-22-2017, 05:21 PM
Part Three
I lived with an urge, perhaps an unstable lust for frame making. It was only the magazines and a book or two I honestly recall where I was standing when I thought “one day I want to design and make frame casting and have own bike shop with the frame building out the back.” I really did have that thought go through my head. I was standing at the work bench with aching legs from the 2 hours of training before work commenced at 8.00am, doing some mundane task such as rebuilding a Shimano B type coaster hub in some kid’s bike for the 4,000 th time, pondering, day dreaming and needing to sate my desire to do more frame work. My enthusiasm for the frame building, to take it further was far greater than the situation would or could allow. Eric has to make the shop pay it’s way and it was toil, toil and persevere at the toil and I was there to do the tasks, chores and earn my wages. Meanwhile I was trying to stay sane with the family home situation by shutting out everything but for training, racing, work, reading and anything frame making related. It was around this time I bought my first lathe, a little Emco Unimat that I kept on a table in my bedroom. I was starting to realise “a lathe is a beautiful thing” .
The day did come , 20 years after the thought went through my cranium but there was a few more steps to take on my time line.

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Dazza
11-22-2017, 05:25 PM
Part Four
Six years at Hoffy Cycles and I had become severely bored. There was a limit to how many coaster hub rebuilds I could suffer. I made my first two complete frames the year before and now I was restless. I chatted to Eric, I asked if I could do more frame building work, I wanted to do more and develop the frame building side, to make it brighter, newer, promote it, inspired by the Italians and I had that youthful enthusiasm that is yet to be dulled by the passing of many laps around the sun. Eric said , “yes, we will have to something……………..” Six months later no movement, then I jumped at the opportunity to work for another chap who built frames in Brisbane. I was 23 and I had to make the change. Any change would be good, but most importantly I was now making frames all day, which then allowed me to start progressing, on someone else’s time. Even my racing improved. I got my 6” lathe and a mill/drill, both of which I still use today. However a year later that frame making gig went bad, the owner and his partner had issues. Left me in the lurch, but two weeks later I got a job at the “Lifecycle” bike shop on the Normanby five ways. Working there was like working in the middle of a traffic island, no frame making but it was a good job and I had few good mates working there, so it was fun and got me involved with retail. It was some time in 1987 that the thought went into my cranium that it was time. Time to start making some frames under my own steam if I am ever going to make frames again. The first thing I bought in 1988 was my 200kg surface/inspection table. $2,000 was a lot gold coin for me back then. It left me broke and totally impossible to have a social life. But for me I wanted to have precision in the build process, so the most important thing is a good alignment inspection table. It should be the #1 tool in a frame maker’s workshop! I still had to wait till I could start making frames, so it was work full time, work in the evenings making jigs, learning the basics of lathe work (only ran the tool into the chuck once) spend every dollar on more tools and still no real social life. Early 1989 I was close to making my first frame as a registered business. No idea what to call the frames. I wanted something related to me, but not “McCulloch”or “Darrello” or one of the numerous other stupid suggestions put to me. “Llewellyn” my middle name, there that will do and I struggled to remember how to spell it. I liked having something that was not main stream but connected to me. So “Llewellyn Custom Bicycles” was registered as a sole proprietor and frame number 001 was made.
I made frames at night when not training or racing, worked on frames on weekends and worked full time during the week at the bike shop. I did start to have a social life, but a few wrong turns along the way, crash and burn etc. A few crash and burns is good for you eh!
I raced, got married. Stopped racing, worked part time in the shop and the other 3-4 days made frames. I had orders flowing. Made a lot of track frames, and 99% were racing bikes. Then I was a bachelor again, so I went to France with some mates and started racing before I was too old and to completely get it out of my system. Age 29-30. That was a great experience, I am very grateful I got to do a couple of seasons racing village races in France. Back to making frames in the summer and working at the bike shop. Came home from France after the 1994 season broke, with glandular fever but did I not know I had it then, got a fulltime job as the road cycling mechanic at the Australian Institute of Sport and with the national team. Lived in Canberra and in Europe. Worked the Worlds and the Atlanta Olympics. Washed Aussie team bikes in 23 countries. Came home, worked in bike shops and made frames and did 6-8 months stints till the Sydney Olympics and the worlds in 2000, now that was a big year. After the big year of 2000 it was time to stay home and ponder what is next.

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Dazza
11-22-2017, 05:27 PM
More next week, got to go and listen to the Ashes contest on the radio.

cadence90
11-22-2017, 05:37 PM
.... ..
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timto
11-23-2017, 08:08 AM
Thanks for all that you do! I have really enjoyed using your custodian lugs and drop outs - I've used your drop outs on several frames. Look forward to the new stuff you have to introduce! For forks - I notice you like to use straight blade forks - there seems to be two options currently - ~40mm inside width , and another that's a whopping 60mm inside width which is too wide for a road bike, where as the ~40 is pushing it for a fat tire road bike which is becoming popular... something right in between would be great!!

Also missing is something straight, 50 width, and INTERNAL crown for those fillet builders like me out there that like a fully smooth look....

Thanks for sharing your story, enthusiasm and making amazing products and being an inspirational crafts person.

bob heinatz
11-23-2017, 02:55 PM
Thanks for sharing your story. Your bike building skills are incredible.

Dazza
11-28-2017, 08:39 PM
Part 5 The Llewellyn frame casting story

While I was galloping about Europe, washing bikes in a different country every week (23 in total) the world of the independent bicycle frame maker was changing and it was never going to be the same. From about 1995 we could say that the Corporations were arriving, Giant, Cannondale etc. The bike industry was becoming commoditised like it had never seen or experienced before. The Corporation’s product was being mass produced in places where labour was cheap. The executives were realising their asperations through the efforts of others. At the Australian Institute of Sport the road team had Giant as a sponsor. Back then these bikes worked well in the harsh environment of a national cycling team. In early 1996 we had the team pictures being taken and the Giant representatives were there, explaining to me and others with extreme enthusiasm and gusto about the new frame size system they were introducing soon. Three frame sizes and with various seat posts and stems so we can fit a bike to anybody. GOOD GRIEF went through my mind! “What could possibly be wrong with that ? ” They thought it was the answer that had never been discovered……………… Any how the steady arriving stream of containers loaded with high end bikes to down under had begun. The bike shop retailers loved it, a phone call, a box arrives, give the tyres some wind, “CA CHING” went the cash register and even that sound was soon to be gone as the consumer racked up their debt on the “fantastic plastic”. The banks are also happy, but they would never admit it, they had their catheters in the punters wallet for a steady income stream of their interest-blood $.
The $ flowed, cycling as we knew it was changing and it was no longer the underground sport that we “Special dedicated cyclists” understood. It was now for the masses and that is good but also a bit sad as something was lost and gone forever. The masses are riding expensive and inexpensive bikes on laps around the river and getting some knick time at the coffee shop after watching the TDF on SBS the evening before. New brands that were popping up when numerous entrepreneurs went to the Taipa show with cash to make the orders and have the containers shipped with their decals. It was feeding the bike industry like never before.
At first it seemed good to me, then to me it seemed shallow and it was about selling an image, it all became a bit kitsch to my mind. People actually thought you need to buy a set of Red coloured special climbing wheels to be able do a lap over Mt Mee on a Sunday with three types of special scientific formulated packaged food bar in your back pockets along with the C02 inflators. Something we did in the early morning before work on our training hack bikes with a banana or a piece of fruit cake in the back pocket with the Zefel pump strapped under the top tube and we rode hard with grace on the pedals. The bike magazines and the internet are telling them this is how you must ride or your health and your cycling enjoyment will be compromised. SIGH!” How to be a better climber in five lessons and …………………” Sigh!
Anyhow, I wanted to stay home in 2001, I had some weeks off over the summer, went back to the bike shop to earn a $. I lasted till lunch time on the third day, my brain evaporated. I could not do it, nothing wrong with the good people there at the shop, they were terrific, it was just that my time in the bike shops was over. It was time to go home and ponder about working for the first time in my life as a full time independent frame maker.
But things had changed, very big and different changes.
The pic is of me working on Deane Rogers bike under the feeble light of a sky light in what looks like a bomb site at the back of the Hotel in Columbia before the 1995 World Championship time trial. Big Mig won. The other pic is walking out into the stadium with the Aussie team at the Sydney 5 ring gig 2000, what a buzz that was.

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Dazza
11-28-2017, 08:50 PM
Part 6 The Llewellyn frame casting story.
2001, I want to make steel frames. Every one tells me I am mad, steel is over. It is aluminium now. Aluminium is a terrible material for a bike frame for many reasons but…………………… I start the process, TIG welding courses and pondering the tool up process. I look at a PC for the first time. How does one work this thing ?
But I like steel, it is strong, beautiful and a wonderful material to work with. It can be used delicately, you can do so much with it and still have a very reliable structure, with brazing via brass or silver and even TIG is one is so inclined. (I am not so inclined) Still every one said I was nuts and I got many condescending remarks out there in the land of bicycles. The irony is that some of them now covet and even own some of my work. I made a vow to myself, ok, if it does not work out for Llewellyn Custom Bicycles within two years I will stage exit right and go off and be a farm labourer or drive a fork lift or drive suburban tin sets or whatever…………………...
Internet, digital cameras, typing, websites, forums , marketing, CAD programs, that was the evening hours after 10-12 hours standing at the bench, while the Australian Broad Casting gave me Radio National or the test cricket. There is a lot more to deal with in the frame making caper compared to the 1980’s and this means a lot more time is consumed that is not bench time making stuff that results in writting the invoice. It was then that my neck discs started to make themselves felt and my arches in my feet started that slide to errrr yukkkk. My grand-father said it was better to wear out rather than rust out but I did not expect to wear out so early. He lived to age 95.
There was no choice but to go down the path of fillet brazing funky shaped tubes from Dedacciai and Columbus. I had done a bit of fillet brazing in the 90s but it was 95% lugged frames back then. Sloping top tubes was the norm now and I did the occasional lugged frame. I got a fair bit of inspiration from Casarti frames in Italy for my lugless work. A couple of times I cast my eyes over their products during visits to the Milan Bike show. I was driven to persevere at the long hours of toil, mostly 7 days a week by the fear of failure. Every dollar was precious (that has not changed) If I failed it was because there was no more I could give. Most important that all of this was possible because I do not have any children. As long as I could eat and pay the mortgage I was OK. I tell this to many budding newbies. Then I had a bike test published in Ride Magazine in 2001 and that caused the phone to not stop ringing. YAY! Phew! By early 2002 I was confident I was still staying on the frame making stage and I could pay the mortgage if I lived cheap. I still did some moonlighting trips with the cycling teams here and there, a couple of Commonwealth Games and trips to New Zealand, France, Italy. That all helped the income stream and was an interesting break from the work bench toil.
The era of the Carbon infestation is getting closer. Tick tick tick tick…………………..
It is 2003, 20 years after that “moment that I can actually recall where I was standing when I thought “one day I want to design and make frame castings and have my own bike shop with the frame building out the back”
It was time to have a go at designing and producing my own invest cast frame parts, but how do I do this ?

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weisan
11-28-2017, 11:10 PM
Good read. Thank you.

Llewellyn
11-29-2017, 01:20 AM
I'm loving this. Looking forward to more...........lots more!

Dazza
11-29-2017, 03:36 PM
WHOOPS. missed a part, I do all this was while doing phone calls, deliveries and neighbours with Cancer.
Part 3 B
Even though I could not ride out of sight on a dark foggy night and my sprint finish was barely detectable with modern scientific instruments, I lived with an urge, perhaps an unstable lust for frame making and racing, I kept finishing second or third until I began to wonder if I was nuts? I trained in all weather, because Sean Kelly would not hesitate to be out training in the Belgium sleet and if the others are at home warm and dry and perhaps cuddled up, I was keeping fit, getting tougher and their form would be slipping……. I did a lot of thinking when training, I think long solo rides are good for your mind, well I convinced myself that it is good thing. No strings in your ears back then, just the sound of the Sanyo Dyno Power rattling on the tyre tread while you squinted to see the pot hole with its feeble 3 watts and that is only when you were going at a decent clip downhill, while the drizzle soaked through your woollen under shirt and your feet turned to prunes, pondering the meaning of life and wondering where and what my school crush, Sonya Housman is……………………………… agh sh-t the Dyno Power is slipping on the wet tyre tread………………… (Some will know what I speak of 😊)
A period of time did come when I had my doubts. Is this frame making caper a wise career choice? All my mates were earning 3-5 times what I was earning or they were finishing Uni degrees. I pondered for some months while riding or standing at bench rebuilding a rusty gummed up Sturmy Archer 3 Speed hub for the 1578 th time, I recalled what Susan Wright who sat next to me in year 7 at primary school said, (or was it that I sat next to her?), any how she had a brain the size of a planet. One day she pretended to read my palm and she said, “you will be a pauper” Such was my ignorance I had to ask her what a pauper is?
So the moment came, when all my momentous life choices are made, probably while riding home 20kms from the shop, usually in the winter dark, most likely raining or into the howling westerly, “Susan is right, stuff it, deal with the consequences of whatever happens, I might well be a pauper via the bicycle world and worse comes to worse I will be just a bike shop owner/worker scratching a dollar here and there, so be it”. This was in the time before cycling became heavily commoditised. The tragedy of this makes you weep eh? No? Oh well, I am not making any of this up. Race now while one’s physical powers are at their best, I never wanted to race as a vet (and I never did) This leads to the moment that I can actually recall where I was standing when I thought “one day I want to design and make frame castings and have my own bike shop with the frame building out the back.” I really did have that thought go through my head. I was standing at the left end of my work bench with aching legs from the 2 hours of training before work, doing some mundane task such as rebuilding a Shimano B type coaster hub in some kid’s bike for the 4,000 th time, pondering, day dreaming and needing to sate my desire to do more frame work. My enthusiasm for the frame building, to take it further was far greater than that current situation would or could ever allow. Eric has to make the shop pay it’s way and it was toil, toil and persevere at the toil and I was there to do the tasks, chores, a wee bit of frame work and earn my wages. Eric was a good boss, I was fond of my time at Hoffy Cycles. Meanwhile I was trying to stay sane with the family home situation by shutting out everything but for training, racing, work, reading and anything frame making related while I started to expand my metal working urges via the pages of “Model Engineer” magazine. It was around this time I bought my first lathe, a little Emco Unimat that I kept on a table in my bedroom. I was starting to realise that “a lathe is a beautiful thing”.

Dazza
11-29-2017, 05:40 PM
Part 7 The Llewellyn frame casting story.
For many years I was making fillet brazed stems to compliment a client’s Llewellyn bike. This came about in the 90s when I was asked to make quill track stems for the trackies. We had a good and fun track racing scene in Queensland but I felt the introduction of summer crits started to demolish the track season which I was not all that pleased about. The growing MAMIL population found it easy to sit on a wheel going around some dull flat circuit that did not even have a corner in it that you had to lift a pedal for, pretending they are Robbie McEwen, compared to riding on the track which took considerable skill, fitness and race craft. (Robbie did ride track in his early days) It is hard to be just an equipment poser when racing track, you look like a real dork if you cannot ride/race the track with grace and technique. Any how I made the track stems from Chromoly tubing, machined the clamps and binders for the steel track bars on the most beautiful thing, a lathe. Chaps and lasses won many Aussie titles on Llewellyn frames and there was a couple of world junior champions as well, on their way to the Aussie national team. Then someone asked me to make a threadless stem for their new lugless Columbus Mega tubed Llewellyn road frame. Yeah, I can do that, so I then made a threadless fork stem for him and that resulted from then on in most Llewellyn frames having a matching stem perched on the fork. Then later I added a machined head spacer from aluminium to grace the set-up, rather than a stack of alloy or plastic spacers. It was a frame, fork, stem, spacer to complete the set, it all was becoming what I consider a “frame set”. It helps flesh out the order book and adds to the invoice which means you stay in business. After all, this is not my hobby, it is my chosen path of professional expression. As the first decade of 21st Century rolled on I was making an increasing number of lugged frames again. YAY! I was trying to stretch my skills with the stainless polished caper, but I began to be dissatisfied with matching up a lugged frame with a lugless stem. It did not seem right to my thinking and my aesthetic desire. I tried one of those lugged stem kits that LongShen produced, but the bar lug had issues, it was for a handle bar that needed to be 26.80 mm in diameter (which is nonsense), so I had to braze a sleeve in and then bore out to 26.00mm in the lathe to fix that. The fork clamp was only for 1” steerer tubes. The extension tube was drop shaped, which was a terrible thing to mitre and fit up for good brazing and it looked too deep for my aesthetic tastes. I made only one stem using that lugged kit. Move on said I.
Around 2003- 2004 the urge to create and produce a stem lug set that does not exist for my needs at the Llewellyn workshop bench was festering into a “need to make happen.” 20 years after that thought passed about inside my cranium “that one day I want to design and make frame castings” I started seriously going down the pathway to do this.
I will often be working away at the bench and a thought will come into the light, I have to stop and go to some scrap paper or my work diary and scribble down ideas and designs. I have done this since I was a budding artist at primary school. I was encouraged to always put it on paper before it is lost. This ingrained habit can cause the flow of some work and other tasks such as typing, posting on forums to be broken as one crams more into each working day, but it is important to me to not to lose the moment so I break the flow and sketch, scribble or make the phone call and so on. Some times I wish I kept all of these drawings and sketches, however I am not on a mission to make a legend of myself and thus keep every bit of paper of my life to regurgitate the banal details to others at a later date or for some museum. I am encouraged by others and with some hesitation on my part to tell the story of Llewellyn. Yeah, perhaps it is part of marketing as well, however I will only give a limited energy to it, because I have other metal working hobbies that scream at me to devote more and more time exploring. If I had the millions in the bank, I would stop making bike frames this afternoon as I can easily sate all my metal working desire via my model engineering projects. Anyone about who would like to Llewellyn outright ? 😊

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Dazza
11-29-2017, 10:12 PM
Part 8 Casting # 1 The Llewellyn Stem lug set.
The sketches of my stem lug desires commenced, I had chats with Kirk Pacenti and a few others about how to go about this project and seeking a foundry to do the investment castings. I had started self-teaching myself via text books in the evenings the basics of 2D CAD drawing and I generated some 2D CAD drawings of the determining dimensions of the lugs. I also contacted investment casting foundries in Australia to consider casting the lugs however when I showed them the drawings they said it cannot be done with such thin walls at 1.20mm. I showed them bike frame lugs castings with 1.20mm walls from Taiwan. That had them standing on their batting crease as if Shane Wayne had bowled around their pads an unplayable delivery that spun and fizzed off the pitch to rattle their stumps. (think of the famous first Test delivery to Gatting) The huge amount of time this project sucked up is immense. It filled a significant part of many days and many evenings and I still had to make frames to fill the orders and earn a $ to live with and also to finance this casting folly so working weekends was required. I would have made more $ if I spent that time filling the supermarket shelves at night but of course, the motivation was to make the vision or dream folly a reality, even if it was just once in my life. It was all to be part of my journey and part of my time line. The drawings evolved and I made the decision to go off shore to Taiwan for the foundry. LongShen have been doing a large share of the steel frame building world’s casting for some time and a few of my colleagues had recently had them successfully involved with their projects. The internet made all these communications much easier than in the decades before and the sharing of info was much increased compared to the 1980’s. Crikey, the silicon chip has moved the world and bicycle frame building was a tiny part of it all.
The most important desires and features were to be
• The fork lug to fit directly onto a 1 1/8” fork steerer tube (28.6mm)
• The fork lug to also fit 1” (25.4mm) with an alloy sleeve such as the one Deda Elementi make.
• To be able to flip the fork steerer lug to get different stem rise amounts
• The handle bar lug to fit 31.8mm handle bars.
• To use a round 28.6mm extension tube for adequate strength and to match the top tube diameter.
• Easy mitring of the 28.6 diameter extension tube and easy perpendicular alignment of the handlebar axis to fork steerer axis.
• Single M6 bolt was chosen for the bar clamp, because the stem is made to length for the bespoke fitting bike and not about seeking a position off a bike shop floor size. Also the aesthetic was to be sweeter and less material required.
• Room on the lugs shore line for the builder to alter to compliment the frame’s lug shapes.
• The lugs would only be cast in stainless steel to avoid corrosion with interface of the handle bar and fork.
I fabricated a sample of the bar and fork lug from machined tube and stock material along with some brazing and shaping. These fabricated samples I still have and the picture is of them alongside the finished cast parts from Longshen.
The samples were sent to Longshen and they have a draftsperson do the working 3D drawings from the samples. The parts were complicated and a lot back and forth was required to get the design sorted. At the time I was learning a lot about the process and language and communications was troublesome but it was all sorted out, mostly with evening emails.
The first samples arrived and from August 2004 I and others have been making lugged stems with these lugs.
However I wish to remind the reader that I do not design and produce these parts or any other frame making parts to tap into a perceived market need of other frame builders. I design and produce the parts for my own in-house production first, because the parts do not exist or maybe the existing parts have shortcomings. I make my living from my hands, so to justify financing the expensive tooling, which was done by borrowing on the equity of the home I then sell the parts to other builders directly or via my agent in the UK and an agent in the USA. It takes about 3-6 years to break even on a part again after the financing interest % is calculated and then one can make a meagre return.
So I happily make stems for the 99% of the Llewellyn owners and over the years I have had many Colnago owners ask me to make a stem for them to fit to their Colnago, I tell them as Ernesto cannot supply you a decent stem to match your bike I will happily make a stem for you and I give them the quoted price, which happens to include a painted Llewellyn frame and fork

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Dazza
11-29-2017, 10:29 PM
Some pics of a few stems going out the door at the world wide headquarters of Llewellyn Custom Bicycles. No chrome ZONE! Stainless steel only


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Another part next week.

54ny77
11-30-2017, 03:57 PM
that there is functional jewelry. :cool:

Dazza
12-04-2017, 03:29 PM
Another Lucentezza build for some time in 2018, I like to break the the job down into smaller bites, so I did the stem lugs while listening to the Test Cricket today.

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Dazza
12-11-2017, 08:39 PM
Part 9 The Llewellyn Casting Story
Casting design # 2
# XLS. The Crescendo Lug set. (formerly called the “Slant 6 lug set” ) Year of introduction 2004.
Llewellyn # XLS “Crescendo” sloping top tube lug set (formerly called “Slant 6”) was the world’s first sloping top tube lug set for road bikes for XL tube size (DOS) and the first Llewellyn frame lug set that I designed and produced.
In 1992 I received my first Columbus MAX tube sets and this set with its bigger than ever before diameters became popular for track riders and road riders who are big, heavy and or tall. Recently the MAX tube set has a folklore legend grow around it which surprises me as there is nothing magical about the MAX tube set. The tube set had a lot more metal and a lot more grams so it felt very firm under the pedal, however one must remember that it arrived in the era of 28.6mm down tubes and even the larger 31.7mm down tubes had only just arrived so the 35mm MAX down tube along with a larger seat and top tube coupled with larger chainstays and bigger MAX fork blades was going to give a very firm frame and this became the new “magic feeling”.
I built many road and track frames using Columbus MAX tubes but it was very troublesome to build with due to implications with the tube dimensions and shaping and also only suitable for 1” forks. It must have been late on Friday afternoon when the person designed the lugs, BB shell and fork crown for the MAX tube set. There is far too much metal along with very bad tube fits, it all looked more at home bolted onto a piece of agricultural farm machinery than part of a fine hand crafted bicycle frame. These lugs and BB shell thus required a fair amount of rectification work if you were to get acceptable results. Cutting, trimming, milling, filing to remove some grams and give a sweeter aesthetic, but after that it all worked for the stronger, bigger rider or those who desired a firm frame under the pedal
It was 2003 and Columbus had long stopped making MAX tubing and lugs and the left-over supply was finally drying up. With MAX fading I needed a replacement for the big, tall, or solid riders with all the desired features required for lugged construction in the first decade of the 21 st Century. After the enthusiasm and toil of the recently completed “Stem Lug Set” I soon started sketching again. I wanted to use a sloping top tube design for reasons of structural merit, (shorter tubes) and this can also allow the use of a taller head tube in frame designs for riders who need their handle bars higher. A bigger 36mm head tube to fit 28.6mm (1 1/8”) alloy, carbon or steel steerer forks and with XL tube diameters that are the same as MAX. The shaping of the large MAX down and top tube to fit the older smaller head tube was of negative value to the frame, however with the 36mm diameter the lug set was to have round tubes throughout which is a plus for torsional rigidity.
I settled on 6 degrees of top tube slope which is an angle that is useful but not so much as to make the frame look like a BMX bike. There was to be ample stack height on the top head lug so it could be trimmed to suit the frame design if required. The bottom head lug needed to have cast bosses for M5 gear cable adjusters with a counter bore for the adjuster spring to nestle into, so when turned it did not scrape and chip the paint off, thus helping to keep a neat and tidy appearance on the finished frame. Those old style seat binder bolts are just plain dreadful, so it will be a standard stainless steel M6 caphead bolt for the seat post binder boss. The top of the seat post binder keyhole slot was to have rounded corners to avoid digging into and damaging carbon seat posts and thus give a more gentle but secure waist type grip on the seat post. I also needed to design enough room on the lugs for reshaping of the shorelines or extra elaboration if so desired.
I studied the tube maker’s available tubes for a useful selection of tubes. To have the seat post fit directly into the Columbus 31.7 seat tube a 30.60mm seat post was required, thus avoiding dreadful sleeves. My US agent at the time and I organised the manufacture of 30.60 seat posts in the USA. I did more sketches with my shoreline inspiration coming from a Bocama lug set from the 1980’s that I had used back then. I then did the 2D CAD dimensioned drawings and LongShen again did their interpretation from my hand fabricated sample lugs to produce their 3D drawings, however there is a loss of interpretation from my samples to draftsman, then onto the tool maker and to the end result of the investment cast lug. No too bad but to my eyes it is there.
The first of these lugs castings arrived on my doorstep and to my European agent “Ceeway” and to my USA agent in late 2004.
This lug set has been a terrific success for my in-house frame building and these lugs continued to be in production and used by other builders around the world to create nice well designed bicycles. In 2017 there was the addition of an optional socket seat stay fitting seat lug (# XLS-04) but that story is to come later.

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weisan
12-12-2017, 06:21 AM
so when turned it did not scrape and chip the paint off

details. details!

Dazza
12-17-2017, 10:47 PM
The third Design and Form by Llewellyn casting, Year 2005

#LL-09-318 and #LL-09-35mm down tube gear adjuster bosses. (The Little Fellas)

STI and Ergo gear/brake levers have been the norm since 1992 however for some combinations of frame designs and component selections one needs a neat and functional down tube boss for a gear cable adjuster to nestle into. For many years I was fabricating my own gear bosses from stamped chain stay bridge reinforcements along with stainless steel stock material, drilling, taping a thread and brazing together onto the down tube. This was because to my mind and eye there was nothing available that was functional or elegant but fabricating these bosses is a time consuming chore. This chore was the motivation to set my mind into motion to design and produce a new down tube gear boss. The new boss will use standard M5 gear cable adjusters (stainless steel, of course). It will have a counter bore for the adjuster spring to nestle into so when the spring is turned so the paint is kept neat. The boss needs to be easy to use in the frame construction process and have a decent amount of shoreline footprint to reduce possible stress risers on thin tubes. Remember these would most likely be placed on the thin 0.40mm section of the tube. During my previous casting projects I was finding that there was always a minor loss of interpretation from my fabricated samples and drawings to the CAD draftsman, then from the CAD drawings to the tool maker. I was motivated to learn how to directly generate the part’s 3D CAD drawing for the tool maker to use directly for the construction of the mould tools to shoot the wax pieces in the investment casting process. It was many long nights along with a considerable quantity of weekends as I worked through several text books worth of lessons with the 3D CAD program. I got to a working process with this 3D CAD tool. It was toil but it was for me to move down my time line of acquiring skills and enhancing the details and results of my work.
In early 2005 I did my first casting project that used my own 3D generated drawing. The pencil sketches that are a close reflection of my fabricated versions were followed by the 3D drawing.

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This new down tube M5 gear adjuster boss I gave the nick name of “The Little Fellas”. Investment cast in stainless steel down tube.

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The shore lines can be altered and the boss polished to provide a detail for some special frame sets.

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soulspinner
12-18-2017, 05:58 AM
The third Design and Form by Llewellyn casting, Year 2005

#LL-09-318 and #LL-09-35mm down tube gear adjuster bosses. (The Little Fellas)

STI and Ergo gear/brake levers have been the norm since 1992 however for some combinations of frame designs and component selections one needs a neat and functional down tube boss for a gear cable adjuster to nestle into. For many years I was fabricating my own gear bosses from stamped chain stay bridge reinforcements along with stainless steel stock material, drilling, taping a thread and brazing together onto the down tube. This was because to my mind and eye there was nothing available that was functional or elegant but fabricating these bosses is a time consuming chore. This chore was the motivation to set my mind into motion to design and produce a new down tube gear boss. The new boss will use standard M5 gear cable adjusters (stainless steel, of course). It will have a counter bore for the adjuster spring to nestle into so when the spring is turned so the paint is kept neat. The boss needs to be easy to use in the frame construction process and have a decent amount of shoreline footprint to reduce possible stress risers on thin tubes. Remember these would most likely be placed on the thin 0.40mm section of the tube. During my previous casting projects I was finding that there was always a minor loss of interpretation from my fabricated samples and drawings to the CAD draftsman, then from the CAD drawings to the tool maker. I was motivated to learn how to directly generate the part’s 3D CAD drawing for the tool maker to use directly for the construction of the mould tools to shoot the wax pieces in the investment casting process. It was many long nights along with a considerable quantity of weekends as I worked through several text books worth of lessons with the 3D CAD program. I got to a working process with this 3D CAD tool. It was toil but it was for me to move down my time line of acquiring skills and enhancing the details and results of my work.
In early 2005 I did my first casting project that used my own 3D generated drawing. The pencil sketches that are a close reflection of my fabricated versions were followed by the 3D drawing.

https://c1.staticflickr.com/5/4689/38242060105_b50ee6bdb1_z.jpg

This new down tube M5 gear adjuster boss I gave the nick name of “The Little Fellas”. Investment cast in stainless steel down tube.

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The shore lines can be altered and the boss polished to provide a detail for some special frame sets.

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Wow. Awesome!

Dazza
01-03-2018, 03:33 PM
What is he building in there ?
what is he building in there ?
And he's hiding something from the rest of us
He's all to himself, I think I know why.................

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Dazza
01-03-2018, 03:43 PM
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Dazza
01-03-2018, 03:50 PM
Big lugs, 46mm HT, 44mm DT
Why?
Kicks and giggles and to sate creativity needs. If you like a firm pedal under your foot and you need lugs...................


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weisan
01-03-2018, 04:52 PM
https://tall.life/wp-content/uploads/2015/12/6foot11inches.jpg

morrisond
03-08-2018, 01:39 PM
Big lugs, 46mm HT, 44mm DT
Why?
Kicks and giggles and to sate creativity needs. If you like a firm pedal under your foot and you need lugs...................


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When do you expect Mega Lugs will be available?

Mattbotak
03-09-2018, 09:45 PM
Stunning and a great read! Lovely to see the process and the frames take shape. Inspirational!!

soulspinner
03-10-2018, 07:08 PM
Awesome Dazza!

Dazza
05-11-2018, 06:07 PM
Painted, assembled, exhibited at the 2018 Handmade Bicycle Show Australia gig. Wayne collected his stead on Sunday, home to Western Australia. Happy chappie!


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Dazza
05-11-2018, 06:17 PM
I have attended four shows in the USA and two in the UK and also the first Aussie show iteration in 2012 which is the show that proved to many of us that an Aussie show has value and is sorely needed down here. I can in full honesty say that the vibe and value of the 2018 HBSA gig that was built on the pioneering 2012 gig is already for me Number 1 of all time.

The removal of show booth war fare extravaganza bull **** that goes on at other shows facilitates and ensures that the spot light is focused and maintained without distraction on the makers and their bikes and or products they make.

That was the intent Ewen Gellie, myself and others desired and the show organisers recognised the value of this.
No effing dioramas, imitation workshops, or 3.5 tons of timber erected in a booth to look like a log cabin…….. Sigh!
The vibe, the process was as if you are at the Tate gazing at a Turner or a Constable. Appreciating the product, conversing with the maker rather than the shallow “Wow” of a conspicuous marketing budget.
Space around the bikes and products, no walls, no banners was very important. Every bike was displayed on the same show provided plinths. The punters appreciated this and so did the exhibitors. If you were there, you would know that it worked splendidly.

The choice of 1, 2 or 3 bike display price options assists the exhibitor to fit their level of expenditure and or level of production. These aspects worked extremely well. I will not be surprised if we see other shows travel down this route. I never build show bike nonsense, I take brand new un ridden customer bikes to shows and sometimes I have a new prototype display bike of a new model or using a new lug design. My three bikes at the recent HBSA gig were all new client bikes. The Saturday night evening dinner for the exhibitors and punters who wanted to be with the makers in the pub next door was a cacophony of high spirits with a decent mix of pragmatic business chat along with the sharing of knowledge and ideas. It was the best get together that I have ever seen at any show I have attended. The show venue only used 50% of the available floor space, so the there is room to expand in the years to come. Michael and Nathon who are the show organisers are very astute professional operators, genuinely caring, observant and they listen and communicate very well. They understood the needs and possible needs of the show in the future and recognise what this niche scene is really about and what it needs. We are very fortunate that the connection with M and N were made. Ewen, myself and others recognise that the HBSA is a valuable vehicle to ensure we stay relevant and appreciated in the market place here down under and also overseas. This show has already given my brand great value and the other exhibitors I have spoken to have expressed the same positive reactions and experiences. I want to add that Ewen and myself have no financial involvement with the show and we paid full $ for our space just like everyone else.
It was all good ! Roll on HBSA 2019.


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weisan
05-11-2018, 09:08 PM
Good points, Dazza pal.

Hey, I spotted a familiar figure in one of the pictures. Is that my pal Ginger? Haven't seen her in ages since our Finger Lake gathering at DBRK. Please convey my regards.

Dazza
05-12-2018, 03:49 PM
Good points, Dazza pal.

Hey, I spotted a familiar figure in one of the pictures. Is that my pal Ginger? Haven't seen her in ages since our Finger Lake gathering at DBRK. Please convey my regards.

Ginger (MAM) speaks highly of her rides and her pals, she misses those rides. I will pass on the message. Pic below of the show and Ginger in Blue.

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weisan
05-12-2018, 05:31 PM
A walk down the history lane...

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bob heinatz
06-07-2018, 11:26 AM
Love the green bike.