Tom gets his Willis bike


The Build up of Tom Adams bike



Nova OS lugset



Picked out the new Nova steel OS road lugset for a 36mm headtube for Tom.





Will cut down the lug a bit for Tom



Tom does not want the tall lug on the headtube so I tried to show how it will look cut down.





Trial mounting in the jig



I cut and mitered the tubing and installed them in the jig. The jig does add some complication but it helps keep it in place.





Trial mounting in the jig



I really need to clean up more.





Needs more work on this joint



Pretty close but I need to get it a bit better fit on this headtube to toptube fit.





This joint looks pretty good now



The joints are starting to really fit well now.





The last joint is almost done



The last joint is just about there then I can put the lugs on. It is funny as people come in and see what I am doing they are all ways surprised to see the fit inside the lug is so close.





The lugs are on



The lugs are all on but as you can see I have a little work on that lower headlug fit to figure out.





Bottom bracket shell



The bottom bracket shell is all ready now.





Blurry seat lug joint



Blurry seat lug joint. I put some holes in this lug to act as little windows to watch the silver flow. The seat stays will cover them up.





All set up



All set up now comes the heat.





Lower head lug



The lower head lug with the little gap pulled in.





Upper head lug



The upper head lug with the extra cut off.





Main triangle



The main triangle is all brazed up.





Rear drop outs



The rear drop outs are brazed on to the chain stays but the stays are not in the bb yet.





Checking the fork



The fork tips are brazed on and I am checking the fit to the crown. But a little while later I saw it was the wrong crown.





Wrong crown



Tom wanted to know how much room he would have for tires. Key point here is wrong crown.





Raked blades



I have raked the blades now. When I get the wheels built I can plain the length of the blades.





Just for fun



I put the fork and the chainstays on to get a picture up for Tom.





The hubs are in



The hubs came in and I am going to figure out the spoke size to use.





The rear hub



High low rear hub.





The front hub



High flange front hub.





The rear hub again



The other view of the rear hub.





building the rear wheel



Here is the money shot Tom, building up the rear hub.





Wheel built



The rear wheel is built and now I need to put on the tire to check the fit in the frame.





Wheel built with tire



Time for fitting.





Stays are installed



Stays are installed and the wheel fits like a glove.





Brake studs



The studs are installed with a very fancy jig to hole the studs in place.





Rear brake housing stop



The rear stop is installed I just got it to stand up on it's own and then heated it up.





Checking the fit



I keep checking the fit. It just seems so easy to make a mistake and not see it until you have gone too far.





Derailleur stops



Another one of my fancy jigs to mount the cable stops.





Clean up time



Time to finish the fork and clean up the frame and order the racks so I can figure out were to put the threaded eyes on.





More clean up time



Well the frame and fork are just about done. I will braze on the eyelets then clean up time. Then off to the paint shop. Start saving your pennies Tom it will be soon now.





Front wheel built



The front wheel is built and now I am just waiting for the racks to come in.





Back from the painter



Just back from the painter.





All done



Okay now lets put it together.





Built up



All built up.





Vintage drive train



Cool vintage drive train.





wide bars



Nice wide bars for big Tom.





Cool Paul brakes



Very cool Paul brakes, I also like the flat crown.





Seat cluster



Seat cluster with the cable stop and rack mounts.





My name



Home made decals.





Head badge



Home made decals of the head badge and way over on the left side you can see our Fatman badge too.





Letter



Nice letter I got from Tom.







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