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View Full Version : Wayne's LLewellyn Lucentezza


Dazza
01-16-2017, 05:09 PM
Wayne's Llewellyn Lucentezza frame set is under way. I feel an off the shelf handle bar stem does not compliment a nice bespoke frame set. I made fillet brazed stems for many years but I felt a lugged stem for lugged bikes was required for my production. In 2004 I set about on my first casting project. I made fabricated sample lugs and did 2D CAD drawings, tools were commissioned and the investment cast stainless steel stem lugs were born. They have real estate to the shorelines for a builder to simplify or elaborate upon. Since 2004 I have made many lugged stems to compliment Llewellyn frame sets. This stem lug set is destined for Wayne's Lucenteza frame set. If all goes well it will be at Bespoked 2017 in April (Bristol UK) before I ship to Wayne in California.

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Dazza
01-17-2017, 06:29 PM
For 12 years Columbus have supplied me 0.80mm wall Nivrocrom tube for making the Llewellyn lugged handle bar stems. This long and fruitful relationship with Columbus continues. This pic is of the first stage of mitering Wayne's stem tube that will be used with the cut lugs.

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Dazza
01-17-2017, 06:49 PM
The Cadenzia lug set emanated from a discussion I had during a visit to Dario Pegoretti's workshops in Caldonazzo in 2009. The name comes from a South Australian wine that I like. This lug set fits XL or DOO size tubes . ("UOS" is a more recent marketed name for the same tube size) For Wayne's frame set I will use for the first time the final version of the new socket seat stay seat lug, which has larger flowing fillets to the surfaces for aesthetic desires.

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Mzilliox
01-17-2017, 07:29 PM
those lugs, oh man, let me pick my jaw up off the floor!

super work!

ColonelJLloyd
01-18-2017, 08:47 AM
Nice! Are these for level (73d) or sloped (79d) top tubes?

roguedog
01-18-2017, 08:52 AM
Dazza, your work is mesmerizing as usual. Just finished looking through the set for the DI2 you posted as well. Just amazing work and detail.

I have to say it again, it is SOOOO good to have you back and posting. Have missed your work, your posts, wallace & grommet and it all.

On the lugs, you said you do things a tad different each time. How do you decide?

Dazza
01-18-2017, 03:34 PM
Nice! Are these for level (73d) or sloped (79d) top tubes?

These are for level top tube, with the new optional socket seat lug for 17mm seat stays.

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Dazza
01-18-2017, 03:39 PM
Dazza, your work is mesmerizing as usual. Just finished looking through the set for the DI2 you posted as well. Just amazing work and detail.

I have to say it again, it is SOOOO good to have you back and posting. Have missed your work, your posts, wallace & grommet and it all.

On the lugs, you said you do things a tad different each time. How do you decide?


Thankyou. The process for me is a sort of nudging into a flavour over the years. It is free hand, I just tweak as I do, nothing too planned, just the "organic" way.

Dazza
01-18-2017, 04:08 PM
This is the final version with revised fillets. I will have these lugs and frame sets with these lugs on show at Bristol "Bespoked" 2017.

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Dazza
01-18-2017, 04:14 PM
Whizzzzz, whrrrrrr, file file whrrrrr, file file file
the die grinder, files and fingers all get a workout

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progress

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Whizzzzz, whrrrrrr, file

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Dazza
01-18-2017, 04:19 PM
Before and after I give em ta Nigella treatment

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Dazza
01-18-2017, 04:25 PM
Done, onto the other lugs today while Pakistan and the Aussies do battle for 50 overs at the WACCA.

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Dazza
01-19-2017, 04:31 PM
Whizzzzzzzzzzzzzzzzzzzzzzzzz is the down under technical term for die grinder operation

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encore the whizzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzzz

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Whrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrr is the down under technical term for drilling

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Before and after shots of the surgery

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Some years ago when I started this style of lug cutting a customer made the comment they have as many curves as Nigella Lawson. After that I used the term, "the Nigella treatment"
referring to her cooking of course.

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Dazza
01-19-2017, 04:40 PM
Whrrrrrrrrrrrrrrrr, whrrrrrrrrrrrrrrrrrr,
whrrrrrrr

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file file file

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scribble scribble (down under technical term for marking out)

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Whizzzzzzzzzzzzzzzzzzzzzzzzzz

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file file file

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It is Wine o'clock, I am off to watch the Aussies chase the Pakistan total
I will finish this lug tomorrow

dave thompson
01-19-2017, 06:27 PM
Great, bike porn and Aussie language lessons all on one page! Great stuff.

Dazza
01-20-2017, 03:46 PM
A wee bit more of the whrizzzzz, whrrrrr and file file

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Keith A
01-20-2017, 03:52 PM
Beautiful...thanks for sharing.

Dazza
01-20-2017, 03:52 PM
Wayne's stainless steel Cadenzia seat lug is done.

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Dazza
01-20-2017, 04:04 PM
By the start of 2005 I was doing my own 3D CAD drafting, rather than farming it out and the resultant loss of interpretation from what was intended in my cranium to what the investment casting became. As an uneducated sod I jokingly called this process my PhD in frame making. I got the large text books and spent many evenings going through page by page the process of parametric modeling. I started simple and in steps escalated the complexity. In 2006 it was time to design and produce the Llewellyn dropouts. I took in the details of good dropouts I have used in the past and mixed in my desires. Lots of time on the 3D CAD program and after confirmations and tweaks via 3D printing some rapids, out of the mix came the dropouts. Hard to believe it was over ten years ago. Crikey! Wayne's drops are on the bench for a wee while of pondering.

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Dazza
01-20-2017, 04:11 PM
Wayne's brief on the dropouts is "one of my favorite details on a Bespoke bike are the dropouts; make 'em gorgeous!!" I give this some thought on the hot and humid Friday. Scribble scribble and then the Whrrrr, whizzzz and file file file starts. I hope Wayno likes this?

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Dazza
01-20-2017, 04:16 PM
These front drops are ready for the cook up. I think they will look sweet when polished and against the paint. Come to "Bespoked" and let me know.

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Keith A
01-20-2017, 04:17 PM
By the start of 2005 I was doing my own 3D CAD drafting, rather than farming it out and the resultant loss of interpretation from what was intended in my cranium to what the investment casting became. As an uneducated sod I jokingly called this process my PhD in frame making. I got the large text books and spent many evenings going through page by page the process of parametric modeling. I started simple and in steps escalated the complexity. In 2006 it was time to design and produce the Llewellyn dropouts. I took in the details of good dropouts I have used in the past and mixed in my desires. Lots of time on the 3D CAD program and after confirmations and tweaks via 3D printing some rapids, out of the mix came the dropouts. Hard to believe it was over ten years ago. Crikey! Wayne's drops are on the bench for a wee while of pondering.


Thanks for the details. BTW, which CAD software do you use?

Dazza
01-20-2017, 04:24 PM
Thanks for the details. BTW, which CAD software do you use?

Solidworks, the reason why was the foundry (LongShen) uses Solidworks as well so it helped the smooth process.

Dazza
01-21-2017, 01:31 AM
"Whoops" "You stupid #%&*#!!!$*&##!! Wally! You will have to start again with another left hand drop"

Do you spot the mistake?

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Dazza
01-21-2017, 02:01 AM
A selection of Columbus tubes in XL, DOO or UOS or what ever you wish to call it, (I call it XL) it is all the same size and the walls and butts are not proprietary.

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8aaron8
01-21-2017, 10:57 AM
You're cooking on this one. Love the signature lug and dropout treatment.

Dazza
01-21-2017, 02:52 PM
You're cooking on this one. Love the signature lug and dropout treatment.

Thank you.

Peter B
01-22-2017, 07:51 PM
"Whoops" "You stupid #%&*#!!!$*&##!! Wally! You will have to start again with another left hand drop"

Do you spot the mistake?

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The shaping is identical rather than mirrored.

This is shaping up to be another beautiful frameset from Dazza.

Dazza
01-23-2017, 02:41 PM
Work on the dropouts continues on a Monday

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Die grinder, files then the sanding begins

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120, 320, 800 and finally 1500 grit under balsa wood sticks. Sanding is the time consuming part of the process and it gives one plenty of time for contemplation about the world whilst listening to the radio

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Polishing takes a few minutes and reveals if the sanding is done correctly

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Wayne's fork blades are ready for the crown

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Dazza
01-23-2017, 02:50 PM
Filing the rear dropouts

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vrmmmmmmmmmmmmmmmm (technical for a buff in a die grinder)

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Gremlins

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Keith A
01-23-2017, 02:52 PM
Wow.

Dazza
01-24-2017, 03:00 PM
Working away, listening to Radio National via The Australian Broadcasting Corporation.

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Llewellyn
01-24-2017, 10:06 PM
And not a lawyer tab in sight :hello::beer: Bicycles designed for people who know how to do up a QR. Really looking forward to seeing the finished product.

Dazza
01-25-2017, 03:32 AM
Tubes and lugs forming up. Die grinder, a bit of time and care and more die grinder, till the fits are eased till all is snug and stress free

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Dazza
01-25-2017, 03:36 AM
Marking out
The head tube is going to get some Llewellyn treatment, I am using a Moore and Wright dividers I got from High School metal work in 1978. Still going strong.

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The crew get to work
dodgy looking sods doing parole work ?

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Dazza
01-25-2017, 03:42 AM
Llewellyn Custom Bicycles head logo is cut by light amplification by stimulated emission of radiation. I then get the Jeweler's files out and dress it up and then press to fit snug to the head tube

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Cooked up and still hot

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Dazza
01-25-2017, 03:49 AM
whrrrrrrrrrrrrr, file file file, repeat four times

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Dazza
01-25-2017, 03:53 AM
Cook up the suit

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Dazza
01-25-2017, 04:01 AM
I got this file in 1987
Lovely lathe file and still used just about every day. The steel was a good brew back then.

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Seat tube to top tube vent

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superbowlpats
01-25-2017, 11:39 AM
Stunning. :beer: how many hours go into a frame like this?

Dazza
01-25-2017, 03:42 PM
Stunning. :beer: how many hours go into a frame like this?

I am trying to track this one in my diary, I always lose count, in the past I have kept records, it was between 200 and 250 hours, this is a genuine number. This does not include the admin of the whole gig and the other interruptions. I only will do two of these each year, and this year is booked out but I might do another late this year. I am pushing hard in the workshop as this frame set will be on display at Bespoked in April.

weisan
01-26-2017, 07:02 AM
between 200 and 250 hours

WOW!

Let's take the middle: 225 hours.

And be extra conservative with the labor $40 an hour.

225x40 = $9,000

Your customer is getting a steep discount!

Dazza
01-26-2017, 04:21 PM
WOW!

Let's take the middle: 225 hours.

And be extra conservative with the labor $40 an hour.

225x40 = $9,000

Your customer is getting a steep discount!

I had to give up looking at the clock or I would never stay sane. (many would argue I lost sanity a while back) however it is my chosen path of professional expression.

Dazza
01-26-2017, 04:22 PM
Stainless steel, delicate shorelines requires a lot more time and care in preparation for the cook up.

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Fork work and cook up while listening to Warner score and score and score

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Dazza
01-26-2017, 04:27 PM
Whoops, dropped it, lost for ever. Get another one, file file , dropped, curse, $#@&@!!!*&!##. Lost two for ever. Then I got two brazed on.

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Keith A
01-26-2017, 04:32 PM
The bottle cage braze-ons are very cool...too bad these wouldn't been seen in real usage.

Dazza
01-26-2017, 04:33 PM
Single point turning the crown race seat to 30.02mm is the only way to go with a stainless steel fork crown. Have I said lately that a lathe is " a beautiful thing" ?

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Peter B
01-26-2017, 10:27 PM
The bottle cage braze-ons are very cool...too bad these wouldn't been seen in real usage.

Lingerie.

Dazza
01-27-2017, 02:34 PM
spot on for the crown race fit

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Careful filing of the surface is the first step. New and sharp file are a must for this.

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120 then 320 grit

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1500 grit under the balsa wood sticks. The sanding takes the time, if done well the polish will be quick and reveal the Lucentezza.

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Dazza
01-28-2017, 04:21 PM
Working up the Lucentezza

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Dazza
01-28-2017, 04:23 PM
The Lucentezza arrives

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Dazza
01-28-2017, 04:34 PM
How I do the internal rear cable. Because this way the tube's durability is not sacrificed. I have seen others have problems :noworry:

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weisan
01-28-2017, 08:22 PM
wow!

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Dazza pal, do you ever do anything simple?
:D

bob heinatz
01-30-2017, 01:46 AM
wow!

https://c1.staticflickr.com/1/506/31764838863_f06f12cc85_b.jpg

Dazza pal, do you ever do anything simple?
:D

You know the answer to that question. Dazza only knows one way to build.

soulspinner
01-30-2017, 07:13 AM
Oh my gosh. Dazza, this stuff makes me crazy and I cant even afford one. Chapeau!!!!!!!!!:beer:

Keith A
01-30-2017, 09:08 AM
Lingerie.Nice :)

Dazza
01-30-2017, 03:20 PM
Oh my gosh. Dazza, this stuff makes me crazy and I cant even afford one. Chapeau!!!!!!!!!:beer:

Thank you and all the others all for your kind comments.
I want to be a bike maker.
The text of a bike maker's life is fluff.
The metal work is what one leaves behind for others to enjoy.

I am devoting a wee bit of time to document this build which is heading to California after a wee loop past the Bespoked show in Bristol. (April 7th-9th)

54ny77
01-30-2017, 10:31 PM
have said it before and will say it again. this is the absolute top of the traditional craft. the top.

i never tire of reading these posts from dazza. don't always comment, but then again don't always see a lucentezza.

Dazza
01-31-2017, 02:26 PM
Pondering some shoreline alterations

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All fits eased, no stress

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whizzzzzz file file file

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Some prep work to some areas of the seat lug to make life easier post brazing

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I was most pleased that the difficult 3D CAD design work I did using surfaces and fills (hard for me as I am self taught via the text books and do all the drafting myself!) resulted in a pleasing flow to the surfaces to the M6 Cap head seat post binder. As I sanded with 1500 grit under the balsa wood sticks I had a wee smile.

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Dazza
02-07-2017, 03:44 PM
The workshop staff are pondering.
"How are we going to do this EPS stuff Shaun?"

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Dazza
02-07-2017, 03:54 PM
Campy EPS cables. Ensuring that the chainstay port allows the cable plugs to pass in the restricted space, proper reinforcement of the tube piecing and to enure the grommet sits snug on flat surfaces so all is well sealed required a bit of work to achieve satisfaction to my mind and eye. I am not a fan of curved plates over large holes with the resultant badly fitting grommets that not always cover the elongated slot........

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soulspinner
02-07-2017, 05:33 PM
Wheres the like button?

Peter B
02-07-2017, 09:31 PM
Dazza is a metal-master!

Anyone contemplating a custom frameset would be well-served to consider a Llewellyn. Mine is a one-of-a kind keeper and this build for Wayne is even a step beyond! :hello:

Llewellyn
02-07-2017, 10:42 PM
Dazza is a metal-master!

Anyone contemplating a custom frameset would be well-served to consider a Llewellyn. Mine is a one-of-a kind keeper and this build for Wayne is even a step beyond! :hello:

This. I've lost count of how many times I've said that mine is the best money I've ever spent on cycling stuff. Mine is ten years old but it still makes me smile every time I ride it. And I've had the pleasure of meeting Dazza :beer:

Dazza
02-08-2017, 05:19 PM
A detail that is often overlooked is the EPS- Di2 down tube cable entry point.
This is a Lucentezza model, it demands attention to this.
I ponder, gears churn inside my cranium
then
I get a piece of rare Columbus stainless tubing that I keep in stock squirreled away for special jobs, for who knows what or when.
I turn some stainless on the lathe for the grommet facet. I drill the DT, I make a template to give me better visual guide to give more clarity of the aesthetic direction.
Wrrrrrrrr, Wizzzzz, file file Whrrrrrrrr, file file, Vroommmmmmm, to the stainless tube. The result pleases me.
I braze to the tube and give it the first stage sand and polish, did not even bother to wipe the dust off before knocking off after a long day in the workshop.

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Keith A
02-08-2017, 06:16 PM
Amazing work Dazza.

JOrange
02-08-2017, 10:55 PM
WOW. Fine craftsmanship right there.

Cicli
02-09-2017, 03:34 AM
Schwing.

weisan
02-09-2017, 06:01 PM
Wayne pal, wherever you are, I just want you to know you are one lucky bastard...you probably already know this. :D

Dazza
02-10-2017, 03:39 PM
EPS FD

https://c1.staticflickr.com/1/700/32445255240_7a297815fe_b.jpg

New stainless steel FD braze on part gets the treatment

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Stem spacer turned from 306 stainless, will be painted with the frame.

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Done at the end of the day, bridges tomorrow

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bicycletricycle
02-10-2017, 06:34 PM
won't that cable port on the chainstay cause the cable to get quickly eaten through by the chain?

Dazza
02-11-2017, 02:45 AM
won't that cable port on the chainstay cause the cable to get quickly eaten through by the chain?

Nope

even allowing for chain slap on a 50T x 11

and the cable is well away from grief with wheel changes.

https://c2.staticflickr.com/4/3911/31990754504_b0ef85c41f_b.jpg

JOrange
02-12-2017, 12:35 AM
Haha, love checking in on this one, never ceases to amaze!

Dazza
02-12-2017, 02:33 AM
No chrome here

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soulspinner
02-12-2017, 04:38 AM
No chrome here

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:hello::hello:

Dazza
02-13-2017, 01:58 PM
I make stuff, keep making stuff, I need to make stuff, making is the substance and validation

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soulspinner
02-13-2017, 04:41 PM
:beer:

Dazza
02-14-2017, 08:10 PM
I did not get a lot done at the workbench yesterday, other stuff to sort through, but before knock off time I got the stainless steel rear drops polished off. I am pleased to say, I am pleased with the shaping. It is a bit different than what I have done on previous Lucentezza frame sets. Thinking back, I remember seeing some of Bruce Gordon's lug work, 8-10 years ago and these dropouts have a similar appearance. Maybe it was stored away in my sub conscience to be called upon later, but as I scribbled on the bare surface of the dropout I was not conscience of such. Who knows what is rattling inside of cranium?

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Dazza
02-14-2017, 08:16 PM
My elaborated use of stainless steel to replace chrome came about after 1997 which was when I last made a frame that had Chrome plating. That bike won an Aussie Vet road title in 97 or was it 98? Any how I was not pleased with the chrome quality. I was prompted in 2001 to visit stainless lug use deeper for aesthetic desires and to refine my use and work with Joe regards to the paint technique, In the long term stainless has many advantages over chrome plating, but it hugely labourious compared to chrome plating. It was all part of one aspect and or direction with regards to my urge to keep refining my work. The Lucentezza frame set using stainless lugs is just one aspect of my bicycle making. It was in 2001 that I returned home to Queensland and went full time making steel bicycles. Up until then I was a part time builder, working at the LBS and spending 6-8 months in Europe as a mechanic with the Aussie teams. I was told by many I was silly to want to make fine steel bicycles in the then age of TIG welding aluminium frames. I was told by some frame making luminaries that I should not make stainless lugged bike frames. ”it is not what we do” was one quote! OK, it is fine if these builders have no desire to make stainless lugged frames. Now that is all sweet and cool, but this potato likes to make a couple of them each year, many are exported to the US, UK and Europe. I do really only like to make a couple of these each year because they are just simply very big jobs. I have a commitment to another Lucentezza frame set build later this year and there is talk of a few more next year.
I do not want to be all things to all people in regards to bicycles. I do not have to chase the market trends to ensure sales are buoyant and thus containers from the wharf keep rolling in.
Making bicycles is my chosen path of professional expression. My flavour is steel tubes, lugged construction and some lugless. If I was young lad today, maybe I would have a different flavour but until retirement I am happy to make Llewellyn bikes for clients to take them on adventures.
A bicycle that gives them many years of enjoyable riding. So with each passing year, their Llewellyn bicycle gives them greater value. Thus they Cherish their Llewellyn. That pleases me.

https://c1.staticflickr.com/3/2194/32784034851_7d9b3582ed_b.jpg

Peter B
02-15-2017, 12:08 AM
<snip>

I am happy to make Llewellyn bikes for clients to take them on adventures.
A bicycle that gives them many years of enjoyable riding. So with each passing year, their Llewellyn bicycle gives them greater value. Thus they Cherish their Llewellyn. That pleases me.



Indeed I do!

Llewellyn
02-15-2017, 01:22 AM
Indeed I do!

Same here Peter. And our bikes have almost identical paint jobs :beer:

Keith A
02-15-2017, 06:28 AM
My elaborated use of stainless steel to replace chrome came about after 1997 which was when I last made a frame that had Chrome plating. That bike won an Aussie Vet road title in 97 or was it 98? Any how I was not pleased with the chrome quality. I was prompted in 2001 to visit stainless lug use deeper for aesthetic desires and to refine my use and work with Joe regards to the paint technique, In the long term stainless has many advantages over chrome plating, but it hugely labourious compared to chrome plating. It was all part of one aspect and or direction with regards to my urge to keep refining my work. The Lucentezza frame set using stainless lugs is just one aspect of my bicycle making. It was in 2001 that I returned home to Queensland and went full time making steel bicycles. Up until then I was a part time builder, working at the LBS and spending 6-8 months in Europe as a mechanic with the Aussie teams. I was told by many I was silly to want to make fine steel bicycles in the then age of TIG welding aluminium frames. I was told by some frame making luminaries that I should not make stainless lugged bike frames. ”it is not what we do” was one quote! OK, it is fine if these builders have no desire to make stainless lugged frames. Now that is all sweet and cool, but this potato likes to make a couple of them each year, many are exported to the US, UK and Europe. I do really only like to make a couple of these each year because they are just simply very big jobs. I have a commitment to another Lucentezza frame set build later this year and there is talk of a few more next year.
I do not want to be all things to all people in regards to bicycles. I do not have to chase the market trends to ensure sales are buoyant and thus containers from the wharf keep rolling in.
Making bicycles is my chosen path of professional expression. My flavour is steel tubes, lugged construction and some lugless. If I was young lad today, maybe I would have a different flavour but until retirement I am happy to make Llewellyn bikes for clients to take them on adventures.
A bicycle that gives them many years of enjoyable riding. So with each passing year, their Llewellyn bicycle gives them greater value. Thus they Cherish their Llewellyn. That pleases me.

https://c1.staticflickr.com/3/2194/32784034851_7d9b3582ed_b.jpg
Thanks for sharing this with us...your work is stellar and I enjoy watching the process of making a Lucentezza.

benb
02-16-2017, 01:09 PM
Incredible! That polished shine is what is missing from Carbon bikes!

Dazza
02-16-2017, 03:27 PM
Do you all want me to "default" my text?

Happy to concede however it makes me feel like I am traveling in East Germany again. Defaulted shall I be?

Dazza
02-16-2017, 03:30 PM
many interruptions take me away from the bench, however but one lug to go

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Keith A
02-16-2017, 03:58 PM
Do you all want me to "default" my text?

Happy to concede however it makes me feel like I am traveling in East Germany again. Defaulted shall I be?Text, what text? We just come here for the pictures :D

Dazza
02-17-2017, 02:23 PM
default - 1
Blue Georgia - 6
Maybe, 3 point is nicer on the weeny screens ?
Any how I am done on the metal work on this one, it is off to get some Joey Cosgrove magic

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Hilltopperny
02-18-2017, 03:18 PM
Absolutely stunning as always:hello: I can't wait to see it after paint so that gorgeous metal work can really stand out!

Dazza
02-18-2017, 04:23 PM
Absolutely stunning as always:hello: I can't wait to see it after paint so that gorgeous metal work can really stand out!

Come to Bespoked (UK April 7-9th)
if all goes well it will be there with the customer's EPS going bizz buzz, bizz when the levers and pedals are played with

Hilltopperny
02-18-2017, 10:19 PM
Come to Bespoked (UK April 7-9th)
if all goes well it will be there with the customer's EPS going bizz buzz, bizz when the levers and pedals are played with

Only in my dreams Dazza, but maybe someday:beer:

pncguy
02-21-2017, 11:09 AM
Alas! I am ruined! No bike will ever be good enough for me now that I have seen this work.

I have never before understood the attraction of lugged construction, but now I see.

Thank you for sharing your labor. :hello: