Cyclocross 2018 

Another great season of cyclocross here in Minnesota! My son, Ethan, moved up into the Juniors class with mixed emotions. He was happy to be moving up with the big boys but not always happy to ride the full course. But as the season progressed he was getting his endurance up more and more! I’m so proud of his progress this year! 

Started the season off at Theo Wirth for the All-City Intercontinental Cyclocross Championships! 

Perfect weather! Cool morning and warm by the time the whistle blew! 

Got to hang out with his CX buddy Roczin! 

Then we skipped a race to do a #BushBuilds Cyclocross Skills clinic with Marcus Bush! Bush taught Ethan and I a lot that day and we made some friends!

Next up was Karma Cross in New Brighton. No major hills, which we both liked but that doesn’t mean an easy course!!! 

Game face for Green Acers! Green Acers CX is the best! Such a fun atmosphere! 

Little Guy Racing CX in Jackson Medow is a really cool race in a really cool spot! 

A link to Jackson Medow.

He got on the podium for the first time in Juniors at Jackson Medow! 

Fulton Star Cross is a night race and usually a wet race! This year wasn’t too bad in Saturday when I raced but Sunday was another story for Ethan! 

Here I am right behind the leader….. after getting lapped! 

Sunday for Ethan….. got dirty! He was really excited to debut his new helmet! I think it still has mud from Lyons Park in Chrystal! 

We then slid on into the MN States CX race! 

I loved this course! I didn’t race it but I rode along with Ethan and it had a little of everything! Twisty off camber, paved segments, barriers, hills, a log to bunnyhop! It was more like going for a trail ride!

Proud to get on the podium! Allbeit 2nd out of 2, it’s the support you get at CX that I love. Seeing his eyes light up when they call his name for the poduim… makes the whole season worth it!

And that’s our 2018 season! 

I’d like to try a XC MTB race this summer too! 

Some cyclocross hecklers came under fire lately. I’d like to share my personal experience. At Fulton Star Cross I shouldered my bike up the big hill to where the finish line is for one lap and I heard a guy yelling “Holy Shit, you better have 2 flat tires! It’s a bicycle, RIDE IT!!!” You know what, the next laps, I rode the mother fucker and damn it, it was faster! After my race he came over and said “You did awesome out there man!” and Hi5’d me!

These are also the same guys that cheer Ethan on when he’s out there! You should see how happy that makes him, hearing them cheer his name and offering encouragement. It’s really heart warming to see!

So you see, hecklers make cyclocross better for Ethan and I so, in my opinion, heckle the shit out of me! I’ll ride better and I know they’ll take care of my son when he’s out in the mud! 

Well, time to get back to building frames! 

#WinterIsHere
Thank you for checking this out!

Allan

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Stepping into the world of the Fillet Braze! 

Now, I love lugs! The lug work of Curt Goodrich, David Kirk and Eric Estlund is undenyably jaw dropping but I have run into too many limitations with lugs. Tube sizes and junction angles are the ones that really get me. 

You see I’m planning a build for my Dad! Yes my Dad is the guy who got me on a bike way back in…. IDK 1983, he used to commute 12 miles to work when I was a kid but had to give it up as he aged. Knees and just lack of time made his rides more weekend geared. Both him and my mom supported my BMX racing habits all the way to the NBL Grand Nationals! My parents moved into the city of Albany in 2011 so then my Dad started riding to work again! He rode an old Trek that I had slapped together for him with some old parts. It’s a pinch too small for him and the thing rides like a brick! Aluminum frame and fork makes for a…. firm ride to say the least. He rode that thing back and forth to work every day, even through the winter! At 70 years old!!!! 

Back in July my parents visited us here in Minneapolis and I had him try my CX bike out. While too small for him he loved the700x40 tires at 35 psi! So we talked about it and decided I’d build him a comfortable bike that can go anywhere! 650b with discs, 1x and a sloping top tube! 

With the sloping top tube and tall head tube I would have had a hell of a time modifying even a sloping TT/HT lug to get the angle I was after. So I needed to step up from MAPP gas and into the world of oxy acetylene. I had been given a rather old torch with tanks and regulators a while back but was a little nervous to use it because one of the regulators was stuck. With zero experience I had to lean on my friend Shawn Peterson. Shawn builds beautiful MTB and Fat Bikes out of his garage that is LOADED with machines and jigs and fixtures. He steered me towards a mini aircraft style torch. The Uniweld 71. I hit up eBay and scored a brand new unit for $25 less than Amazon! 

I ordered up some Gasflux bronze and flux from Framebuilder Supply as well. Its kinda the industry standard so, knowing what I know about fillet brazing at this point (aka nada), I don’t ask questions and go with it.

Now if I could help one person to buy the correct hose I will be a happy camper. In gas welding there are 2 styles of threads. The A size is a 3/8-24 thread and the B size is a 9/16-18 thread. This Uniweld 71 torch and most other aircraft torches have A sized threads. Your regulators will more than likely have a 9/16-18 outlets. So you will need to find hose with A sized threads AND B sized threads. I noticed I could only find that combo with 3/16″ ID hose, which is perfect! Don’t fuck around with adaptors and shit just buy the right hose. Go to your local welding supply place to get the right stuff. 

I still need to buy flashback arrestors! From what I read it’s unlikely that you will ever have fire go back through your hose and into the tanks (boom) but arrestors will make sure that can’t happen! 

Then there is the tip. (Insert “just the tip joke”) From what I am finding, for fillet brazing you want a small, cool tip. I started with a Uniweld 17-1 tip (or most call it a #1) and then got a smaller 17-0 tip (#0). So far I like the #0 better. I think as I get more control over the torch I will switch back to the 17-1 for faster heating. Right now I don’t mind taking my time with this.  

Kirby was really excited for fillet brazing! 

Theres the hose on the torch. Almost ready!

Since the regulators I had we’re 50+ years old and shot I picked up these middle of the road regulators. They aren’t Uniweld or Victor but they’d “get me into a lot of trouble” according to the guy at the local welding supply place. 

FIRE!!!!!

For safe keeping of my tanks I cut a 2×4 to fit across 2 studs in my garage then ratchet strapped the tanks to it. That outta keep them in place! 

I was so excited to give a fillet a try, I grabbed some tube cut-offs and Brazed them together…. well, by definition I brazed the together. In reality I used WAY too much heat and all the bronze I put just sucked in-between the tubes, not building ANY type of fillet what so ever! 

Ok, I need help! Luckily Joel Greenblat of Clockwork Bikes was amazing enough to envite me to his shop so he could show me what I needed to see! His shop is like a playground! Alignment table, lathe, mill, gas fluxer, tube sets, a sanding belt mitering machine and some beautiful projects hanging on the wall. He lays down a perfect fillet in about 1 minute! 😲 Then with the torch in my hand, walks me through the process. Thankfully he’s a patient teacher because again I started dumping too much heat into the joint. But he gives me more pointers and works me through another joint. 

Back home I try another fillet. Seems like getting a really cool, quiet flame is what’s needed. I tried taking g a pic of the flame but it’s just too much light for my phone’s camera. This next fillet came out a bit better. 

Once again Nate Zukas shared some info with me on Facebook about building a “dam” fillet then using gravity and that dam to contain the current puddle of bronze. That seemed to work well with me. Sometimes you just need to hear the same thing in a different way for it to click. 

I cranked out a few more practice fillets and am definitely seeing progress. I still have a LONG ways to go as I would like to be able to leave some fillets “raw” as I feel that is the most honest way of showing ones skill. Zukas and Mars Cycles both do this really well! 

I wanted to practice a joint similar to what I would be doing on my Dad’s frame so I grabbed the 2 tube sizes and mitered them to the angle to be built to. 

Trying to keep the miters as tight as possible. 

Flux.

Tacked it.

Then took it out of the jig to lay down the fillet. 

Das Fillet!

Now I had the task of cleaning the fillet up. Man, this is TIME CONSUMING! 

Again, I still have QUITE a ways to go but hey, if we aren’t pushing ourselves then we won’t get better. 

If I haven’t bored you to death yet, check back soon for updates on my fillets and progress on my Dad’s frame! 

Have fun!

Allan

Bike commuting for the WIN and a review of the Timbuk2 Tuck Pack! 

Ok, so soon, I’ll get back to building frames. I just need to finish some component designs first and machine them up! 

Meanwhile, I am really excited to be able to say that I was able to make a tank of fuel last 1 month! Yes siree, today is May 21st and the last time I filled my gas tank was April 21st! 

I drive a 2004 VW Passat Wagon with 160-something thousand miles on the clock. I did the timing belts at 140k and that’s about it. (engine wise) It’s been paid off for a while now so all I’ve been paying on it is fuel, oil changes, tires and brakes. My last job was 36 miles each way and I was starting to hate the accelerated wear and tear on it. 

As an added bonus, I’m going from 2 tanks/week to 1/month! At ~$3.10/gal that’s about $280/month I’m saving! 

Maybe I’ll get a cheap fat bike for winter duty but for now I have the best dang blue commuter/cross racer to ever come out of my garage! 

To celebrate, I just ordered a new Timbuk2 Tuck Pack roll top back pack. I absolutely LOVE my Timbuk2 Raider pack but it is really only good for carrying a few things. Since I eat a lot, I have room for my days food and that’s about it. The other day I wanted to bring a few other things and the Raider pack was TIGHT!!! 

As you can see my Raider pack is pretty full and this is just enough food to get me through a 10hr day! 

The Tuck Pack is a simple bag with a large opening on top, a side access zipper for a laptop (which I never really plan to carry) and a front pocket that opens vertically. Timbuk2 makes a lot of packs with vertical zippers so you can get to your stuff by pulling one arm out and slinging the pack around to your side. 

Probably the coolest aspect to me since I don’t like the idea of wearing grey/black when I ride (you know, the color of pavement) is that this pack is flaming bright ass, stare into the core of the sun orange!!! Also for added visibility there is a strap towards the bottom of the bag for an additional tail light. BE SEEN!!!!

And it looks great with a Yellow Lab!

But then again, what DOESN’T look great with this handsome son of a mother. By the way, for this pic (above) I put the Raider pack INSIDE the Tuck Pack! 

Chillin’ with a seal at the Minnesota Zoo. To give you a size reference, I’m 6’3″ and about 200lbs. 


If you ever read a review and the reviewer has nothing bad to say about the product they are reviewing then they were probably paid for the review! So, onto what I don’t like about the Tuck Pack. There are very few pockets inside. True it has a laptop sleeve but there are really few places for other smaller stuff. I always keep a small first aid kit, a tube, keys, a spare shoe laces, patch kit and other random things in my bag. The first aid kit fits into one of the few pockets inside the main compartment really well but my tube is just tossed in the bottom. No biggie really. The front pocket is the same. Large with no added pockets. Now, for the FRONT pocket, that is A-OK with me but the only thing I feel is a MUST that the Tuck Pack doesn’t have is that little safety latch for your keys. You know the one that’s on a little piece of “ribbon” for lack of better terms? I really miss that! I will probably add my own soon! 

Still, I would highly recommend this bag! Bang for the buck, it’s unbeatable!

My bro-in-law, @unfunnymike on IG, introduced my wife and I to Timbuk2 about 6 or 7 years ago when he worked for them. We have sinced gotten backpacks, messenger bags and even luggage and even my wallet! We haven’t been disapointed with any of it!   

Here is a link to the Tuck Pack if you wanted more detail. 
My wallet:

 

Winter Riding

Ok, so I’m a big wimp!  Especially when it comes to riding in the cold. Yes, I’m from New York originally but I’ve spent a 3 years in the Caribbean (St. Kitts) and 4 years in California so my blood has thinned. Plus there’s a reason why we left NY and it’s not in search of better pizza! 

Well, now we live in a place that is colder than Alaska and winter just will NOT quit! 😂 We had 16″ of snow down here in Bloomington over the weekend of APRIL 14-15 (2018)!!!!!

A couple of weeks ago it was nice enough and almost all the snow was gone so I figured I’d go for a ride. 38°, a light breeze, cloudy skies and a few flurries. Seemed like as good a chance as I was going to get. I bundled up, light layers, insulated running pants over my shorts, 2 pairs of socks, long sleve tshirt, thermal shirt, sweatshirt, Home Depot work gloves and a 45North cycling cap under my helmet. Good to go?

I set out and seemed fine once a little body heat got built up. Then I hit a slight downhill headed into the wind. My face was FREEZING, especially my eyes! It had gotten painful to the point that I was about to stop and take my glasses off so I could put my bare hands over my eyes to warm them back up but I pictured all of the people fat biking on frozen lakes out here and decided to forge on. (Told you I’m a wimp in the cold!)

Once making it past the downhill headwind I was fine. Rode to Bush Lake and snapped a couple pics.

On the trip back, it was all tailwind, even the downhills were better but my face was still cold. When I got home I questioned how the hell I was going to make it here in Minneapolis and it dawned on me. You don’t have the right gear! “DUHHHHH!!!” all you northerners are saying. 

I ordered ski goggles and a blacalava! 

In this time I started a new job that’s only 3 miles from my house! So I put my new stuff to the test at 29°! I added a soft shell jacket, ski gloves and jeans over my insulated running pants. As soon as I set out on my new fraction of a commute I was AMAZED by how comfortable my face and especially my eyes were! Even the same downhill section was nothing! My head was a little chilly but I could always add my 45North hat to the blaclava. I was really happy with my purchases and the fact that I was able to ride below freezing!

I’ve commuted a few times in similar temps and I can say that I could probably ride at 20° with the same gear just fine. 

The next test is the snow. Luckily we we’re dealt enough to give a snowy ride a whirl. I bundled up in the same commuting gear AND the 45North cap, aired the WTB Nanos down to 30psi and head out. We had about 4-6 inches by then. Pointed my ship to the nearest uphill in the neighborhood to test traction and was quite surprised. The Nanos dug down and pulled me uphill with ease. Then I tried a sidewalk with more like 8-10 inches on it and was totally stopped dead! Ha, so I guess I found my limit there!

By the way the temp was 25° and the goggles, hats and ski gloves we’re all working VERY well together! I rode myself over to a local highschool that had been recently plowed and the bike handled great in the roughly 2″ on the parking lot. 

Just about then I saw lightning! Thunder rolled across the sky from North to south and I figured I’d better boogy on home. I was hoping for a longer ride but I also don’t like being struck by lightning. But as for comfort, I was just right! I am very confident I could commute down below 20° at this point and that really warms my soul!

My main takeaway from all of this is that you need to take measures to take care of yourself! I was at a job with a few toxic people that was too far from my family and home. So I waited and found a job where the people are welcoming, positive and appreciate the skills I bring to the company! An added bonus is that I can now commute to work by bike! Between these things they have already made a noticable effect on my mental and physical fitness. So don’t expect things to change. Get out there and do it yourself! 

Have fun! Be safe!

Allan

My son raced his first Cyclocross race!

I told my 8 year old son, Ethan, that he could race cyclocross if he wanted. His reaction was “REALLY?!?!?!?” ,with the widest eyes ever! So naturally it’s father/son bonding time! Minneapolis, Minnesota, as it turns out, has a great ‘cross scene with races every weekend and “Kid races” at every event! 

What bike would he ride? I really wish this was another frame build post but the darn kid is growing so fast, and I’m not exactly that fast at this yet. He had been riding his 18″ MirraCo BMX bike but it was getting a bit small (even for a BMX bike). Well, my wife used to race BMX too and we still have her trails bike! Perfect! 20″ We The People Ovoid! I replaced the grips, pumped up the tires and raised the seat a little bit. Perfect “BMX” fit! 

Time for his first cyclocross race!!! If you’re thinking of taking your kids to a ‘cross race, do it! They do such an awesome job of encouraging the kids! 

All-City put on a great event at Buck Hill, a ski center just south of the cities.

He was SO pumped after his first race! 

RevoX Cross was a lot of fun! We got to almost take a full lap around the full course after the kids race. That’s when he realized how difficult a cross course can be! 

The water was surprisingly warm! 

Next up was FreewheelCX at Rebecca Lake.

After FreewheelCX he asked me for a bike with gears! Ha! He’s starting to get it!!! Soon enough buddy!!!

We found a bitchin’ playground at the park just after the race! 

A firetower with slides!!!!!

Next up was Green Acres CX, this is the biggest race we’ve been to so far and also MY first race! Ethan did well but struggled with the one speed. He asked the person starting the kids race if their was a single speed kids class. Haha! 

There was a really fun berm at this race! “Go high or go home” was being heckeled at the big guys so Ethan wanted to prove that he could “Go high”! He definitely went higher than some of the big boys! Not bad for an 8 year old.

So yeah, I raced. Holy shit it was probably the hardest I have ever worked on a bike! Also some of the most fun I’ve ever had on a bike! I realized that I don’t have the legs I had in California. No real excuses in that department, but it was still a great time! The atmosphere at Green Acres CX was like a festival with a food truck, beer, HED and Salsa booths, team tents and trailers, a place to hose down bikes and even a Shimano repair guy! They also had a fire pit which was good because us Californians aren’t used to 50° with a breeze! Haha! 

Next up tomorrow is Little Guy Racing’s event! I’m sure it will be as good as the rest so far. I’ll continue to update this post as we hit more and more events.

Edit: 10-30-17

This past weekend was Karma Cross! The venue was great! A park in New Brighton, MN with a spot for a hockey rink, a warming building with bathrooms, a playground for the kids and a sand pit! (Volleyball court really) I didn’t race but I did get to take a couple full lap. The course was soft, twisty and muddy. 

I loved how they had the kid race on a shorter but still longer most of the course! Probably the longest kid course I’ve seen! Perfect place for Ethan to try out his “new” mountain bike. 

The fatter tires and gears served him well on this course! 

Time to warm up and dry off with his buddy Rocky. 

For now, have fun and stay safe out there!!!!!

Allan

Yeah so we’re moving to Minneapolis!

My wife got a once in a lifetime opportunity so for 3 years we will be living in what I’ve heard is quite an amazing bike town! Very excited!!! So at the end of August we’ll be headed out there. So keep an eye here as I’ll post some road trip pics and stuff.

I’ll definitely miss what LA has to offer but look forward to new adventures! 

My Interview on the Locked In Show! 

Here is the interview Mike from the Locked In Show on YouTube did with me! 

Let me set the scene here for you. Mike came up to my garage (shop if you will) and I gave him a little more rear end clearance. His rims are really wide so it made the 35mm wide tire both wider and larger in circumference. So he got a seat tube dimple! Now he has 3 mm of clearance! 

Mike uses the same pedals I do so I tossed my shoes on and took it for a little rip. First thing to note was the weight, 18 lbs with 29er wheels and 35mm tires. Acceleration was WOAH! Second thing of note was the smoothness when seated and the stiffness when out of the saddle! IDK how that’s possible but… Columbus Spirit I guess. The third note is how cool eTap is! 

Oh, also, it was 110°F before we closed the garage door to do the interview. So, call it 115° during. 

Well, without further adue, click the pic below! 

Two things for me to take away from this.

1. People tell me I really sound like this! 

2. Mike is rad and it was really fun doing this! 
The bike came out bitchin! Just wait till you see what he has in store for the paint! 

Till next time, hug your kids, adopt your pets, do good shit like donate a few bucks to your local food bank when you can (some of your neighbors rely on that), wear a helmet, turn on your lights, buy something little for your partner to say you love them just be-freakin-cause, eat desert and say “Hi” and smile when you see people! Anybody! Doesn’t matter who or what they look like, what they’re riding, (or not riding), what color, religion or country they’re from because a smile is a universal symbol of peace and we need a shit load more of that in the world! 

Wow, that got deeper than it was supposed to! 

Have fun!

Allan Varcoe

Gear Shift Lever Boss Replacement Sauce! 

I got a message from Jorge that he needed help with replacing the DT shift lever bosses on his Surly.  I’ve never done gear shift bosses before so this is the perfect chance to make a fixture for doing so! 

Come to find out Jorge was referred to me by Jared Jerome of Jerome Cycles in Los Angeles. Jared builds some of the sweetest city bikes you’ll ever see so it was an honor to be referred by Jared. 

Jeorge came up to my place to deliver the victim and we had a nice chat. Turns out this guys got a ton of bikes. My kinda guy! 

When it comes time to design and build a new fixture you don’t have to twist my arm. Hopped onto Solidworks (which I am JUST starting to get a handle on the very tip of that iceberg) and put my ideas down on pixles. Came up with this little guy. 

Took the model over to Mastercam and blasted out some high speed tool paths!

Then since our 4 axis was busy, I stood the part up and drilled the holes. First with a normal length drill and then took it up to level obserd with the really long drill! 

Whalah!!!

Now onto the real thing! Here are the mangeled bosses. 

Fluxed and heated the old bosses came off nicely. 

Then I soaked off the flux and filed the brass off. Now for the new fixture! Cleaned up the tube and bosses, refluxed and rebrazed! 

It held great! The bosses are colinear and level! Exactly what we want! 

I posted a few pics of this on Facebook and IG and got some interest in this fixture. So I plan to knock out a handful or so more of these in the near future. Probably the last week of July (2017) so if you’re interested, shoot me an email.

allan@varcocycles.com 

$50 shipped in the USA (little extra for the rest of the planet)

So, as always, till next time, keep your frikin’ head on a swivel, turn your lights on day or night, wear a damn helmet and go have some fun! It’s summer!

Allan Varcoe

The Gravel/Do All Frame That’s Light Too!?

A little while ago I got an email proposing a really cool project. It was from Mike Shrewsbury of the Locked In Show on YouTube. His channel is mainly focused on fixed gear products but he is starting to branch out to cover Mikes other cycling interests. Mike wanted a custom frame that could fit his long torso and clear a 700x35c tire. He had some good miles on a Specialized Tarmac and felt it was a very close fit for him. Mike most recently had a Specialized Crux which he liked but wanted a little crisper steering and didn’t need the bigger tire clearance down in Long Beach California, land of sun and sand. (and no mud really)  He was also looking to keep with the weight (minus pedals and cages) at 17 lbs! 

Hell yeah I’m in!!!

This was a job for Columbus Spirit! Many classic builders regard Spirit tubing as the holy grail of lightweight and ride quality so I had to give it a try while adding my modern twist. By modern twist I mean a sloping top tube, internal cable routing, no shift cable guides (SRAM eTap) and flat mount disc brakes! Oh yes!

Spirit, Paragon and Lewllyn lugs! I wasn’t able to use the lugs because I didn’t realize that he only makes this set for 1″ sterrers. So, Long Shen “Slant 6” lugs were a better fit. Thankfully Nova Cycles was awesome for the whole return/exchange.

Got to work with some engraving. A little Mastercam-ing and some CNC-ing.

Next I wanted to machine the “Gaviota” logo into the HT directly instead of a badge.  So…

With those two done it was time to start on the Spirit tubes! They are so thin, lightweight and brightly finished I was hoping they’ll be as nice to work with as they are to look at and handle. 

I used brass for the cable guide tubes in my VarcoCross build so I wanted to try stainless and I’m glad I did! I like the idea of using stainless on places where things touch the frame. I also needed to use some sort of cable guides reinforcements because of how thin walled this tubing is. 

Sawed a set out then I finished the shape on a bench grinder. 

I brazed the guide tube in first to make sure I got a good attachment before adding the reinforcement plates.

Finished off…..

Out of order here but… This build will also mark the first time I use my frame fixture/jig for the entire build so there was a little learning curve for that but it went pretty smooth. 

Paragon Flat Mount dropouts are great because you don’t need a fixture for the post mounts. Just braze them in. Here are the dropouts brazed to the chainstay but there are more pics of the flat mounts further below.

Because the rear triangle was to be short and the seat stays attach low, I needed a little bit of extra room up at the seatstays for the wider tires so I decided to give my fork raker a shot at bending these. 

For slotting the seat stays to accept the dropouts I have a neat little fixture to hold two of them at the same time. 

Now, seat tubes are only single butted so they are thinner at the top. If you are going to join the seat stay tops to the seat tube it isn’t a bad idea to reinforce the seat tube. I cut a section of tube and shaped it to mock the contour of the seat lug. 

Ahhh, plenty of room! 

Next up is the internal HT reinforcement. 

And a few braze ons… (Water bottle mounts in 3 places)

Soak it and clean-up…..

You can see the flat mounts brazed in here. 

And here. 

There it is. My first Gravel Grinder build! And, it weighs just 4.25lbs!!!! For a 56cm!!!!

Check out Mikes channel for videos about this build! Locked In Show

That’s it for this one! Keep on checking back because I’ll post pics of his complete bike as he finishes the build! 

As always, wear a damn helmet, turn your lights on and LOOK where you’re going! Have fun and ride safe out there! 

Allan Varcoe
Progress shot!!!!

6-19-17

7-1-17

Got this beautiful pic texted today. 

9-14-17

He’s got it all painted up and looking amazing! 

The VarcoFrog?

Yes sir, the VarcoFrog! My buddy Lawson aka: Frogi was looking for a frame that fit him to be used in fixed gear road crit races and to bomb around the streets of the ATL on. 

We chose Columbus Zona tubes because of it’s toughness, ride quality and light weight. The top tube is 7/5/7 wall but to add to the stiffness I used an 8/6/8 wall downtube. These numbers refer to the wall thickness of the tubes. Most tubes used in bikes have “butted” tubes. This means the wall thickness is thicker at the ends, where the junctions are and thinner in the middle where strength is not as important. 7/5/7 means the tubes wall thickness changes from .7mm at one end, tapers to .5mm in the middle, then back up to .7mm at the other end. 

Miters need to fit tight even under lugs! 

Vent holes. I’d like to make em bigger. 

This frame has a 100mm head tube so the lugs had to be modified to achieve such a diminutive number. 

Here my QC department checks that the seat tube slot lines up with the slot in the lug. 

They’re not impressed. 

120mm track width!

Doing a fastback again. I love fastbacks thanks to Ben Serotta!

Next is badges. I wanted to use the Gaviota logo and add some type of BB tag with name and number of the frame. 

This Froggy is done!!!

Frogi is going to paint it himself so I can’t WAIT to see what he comes up with. I really like the way this frame came out and I hope he does too! I also hope he rides the shit out of it!

Have fun and stay safe everybody! 

Allan Varcoe