The welding of bike frames involves both science and art. Metal expands when it is heated and it contracts when it cools. We use our own custom heat sinks to reduce this expansion and contraction, but it can not be eliminated. When multiple tubes are connected to one another, this expansion and contraction can cause the frame to distort. The welder's job is to not only make beautiful welds, but to weld the frame in a sequence which will balance off the distortions which are generated from the expansion and contraction.

29.
Inspect frame and compare to Work Order.

30.
Place frame in alignment table and mark to guide in welding sequence.

31.
Plan welding sequence for the frame.

32.
Install heat sinks in heat tube, bottom bracket and seat tube to help reduce heat distortion from welding.

33.
Install proper spacer to set rear axle spacing.

34.
Weld all tubes according to welding sequence plan.

35.
Weld in head tube gusset.

36.
Weld in end caps and let frame cool.

37.
Place frame in alignment table and cold set if required.

38.
Make seat stay bridge and chain stay bridge and fit to frame.

39.
Miter brake mounts and fit to frame.

40.
Tack and weld bridges and brake mounts.

41.
Place the frame in the alignment table and cold set if required.

42.
Perform wheel check to make sure wheel is aligned in frame.

43.
Install heat sink between dropouts and weld dropouts.

44.
Quality check of welds before passing on to Finishing Department.

Next Section: Finishing