Aluminum inserts machining and anodizing

The bottom bracket converter BB30 to Bsc73, an Heckler pro pack and a Tallboy derailleur hanger were used to simplify the work.

I did all the other axles and inserts on the lathe of my friend, and he cutted the Yoke with an EDM out of a 7075 aluminum block.

For the head badge, I simply used a 1mm thick aluminum sheet and bent it to the headtube shape.

Then I shipped the batch of parts to the anodisation company near Besancon.

Bonding inserts and finishing

Once the parts were cleaned, there were bonded inside their respective holes with Permabond ET538, which cures really slowly (2hr working time) and does have good flexural properties which help to prevent cracking.

For the frame decals, I designed a logo on Creo and request a quote for a black sticker.

Once bonded to the frame, the varnish would protect it.

In order to fill the pinholes I used an epoxy resin and alternatively a VM100 adhesive to repair the bigger imperfections as it cures quickly and is already black.

For the final finish I just key the surface with 400 grit and clear-coat with any automotive paint.

I 3D printed some cable routing inserts which were painted black and bonded to the frame.