Building up a Colombus fork


New fork



Vintage fork blade



Picked out a set of pre-raked Columbus fork blade.





Laying out the blades



I like to lay the parts of the blade out to start getting a feel to the cutting I have to do.





Setting the rake



I am looking for a 43 mm rake this is about were the drop out will be to get that.





Marking the tips



I marked were I will be cutting the blades.





First cut



First cut.





First cut done



First cut is all done.





Cutting the slot



Cutting a slot for the drop out to fit. I use a small cutting blade.





Clean up



Clean up the slot with a flat file.





File the sides



File the sides of the blade to give it a cleaner look.





Clean up the inside



Cleaning up the inside of the fork tip.





Just about done



Just about done with the cutting of the tip.





Test fit



Test fitting the drop out in the new slot.





Second blade



Starting with the second blade.





Done



Both fork blades are cut and fitted to the drop out now.





Testing steerer



Here I am test fitting the steerer into the fork crown.





Testing



Test fitting it all together to figure how much of the upper part of the blade to cut off.





In jig



I put it into the jig to see how it looks and put a file under the blades to see if the distance is even.





Ready



All ready for flux and brass.





Cleaning



Cleaning out the fork crown.





Flux



The fork is fluxed.





Oops



Oops forgot the vent holes.





Done



Both vent holes are done.





Tacked



I tacked the parts all together to check out the fit.





All brazed



All brazed up and starting to clean it up.





Cutting



Cutting and facing the fork crown.





Helping



A little help from the fat-men.





cleaning



More cleaning.





Alignment



Checking the alignment of the fork. A little cold setting was needed.





Ready to ride



All done and it is back on the bike ready to ride.




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