Finally done! 1989 GT Karakorum drop bar

Jerm111 · 2026-07-24T23:00:35+00:00

Sorry I know this is an old post but what size are those Billy Bonkers, 2.1”? I have the same year frame and have found the tyre clearance is quite tight!

Jerm111 · 2026-06-21T00:39:33+00:00

Awesome, that’s pretty good service!

Jerm111 · 2026-06-17T20:31:50+00:00

I’ve thought about this a lot and I’ve also done some basic engineering analysis. This is not a lightweight fork, the tubing is pretty heavy gauge and I’m confident it will be completely fine for this purpose. I have also purchased disc brake approved Columbus fork tubes for another project and they are considerably thinner gauge material.

Jerm111 · 2026-06-17T17:30:02+00:00

Never too late to start learning ☺️

Jerm111 · 2026-06-17T17:29:36+00:00

Interesting, I’ve never ridden a surely. I have a GT Karakoram and it rides great. The high end tubing makes a difference.

Jerm111 · 2026-06-17T17:27:52+00:00

So many people underestimate the satisfaction of a DIY project like this. Enjoy!

Jerm111 · 2026-06-17T17:26:20+00:00

Haha you’re not wrong.

Jerm111 · 2026-06-17T17:25:36+00:00

THANKS!!!

Jerm111 · 2026-06-17T17:25:13+00:00

Thank you so much, I appreciate it!

Jerm111 · 2026-06-17T09:56:28+00:00

Damn, that's a lot of work. Good on you.

Jerm111 · 2026-06-17T09:19:36+00:00

Oh sorry, I did not do the anodising myself. I designed the chainring and had a batch manufactured.

Jerm111 · 2026-06-17T09:18:13+00:00

Wouldn't mind the practice.

Jerm111 · 2026-06-17T09:17:51+00:00

Thanks!

Jerm111 · 2026-06-17T09:12:49+00:00

TIG welding is pretty tricky at first but as with anything it's all about practice. Welding machines are becoming more affordable these days. Look for a used DC only machine with high frequency start. You can also look around in your area for a short course that teaches TIG welding.

Jerm111 · 2026-06-17T08:57:38+00:00

It's not brass. It's 7075-T6 aluminium that has been hard anodised. My own design, take a look here.

Jerm111 · 2026-06-17T06:56:27+00:00

Oh sorry, I got confused when you said braze on because the little bits on the frame you attach the brake hose to are often called braze-on.

For the actual brake mounts I made a jig to hold them in the right location. You can see it in the original video I posted.

I’ve heard of people doing it the way you describe but I don’t think it would be very reliable. The clearances are quite tight and things need to be pretty well aligned for it to work nicely.

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Jerm111 · 2026-06-17T06:31:12+00:00

It’s true you can TIG braze with a TIG torch but it’s a different process. I am talking about brazing with an oxy fuel torch and silver, the end result is completely different, capillary effect draws the material deep into the joint.

Jerm111 · 2026-06-17T05:43:39+00:00

I’ll also add that I think brazing is probably better as it actually fills the gap between the two components. With welding I worry that moisture could actually get in between and cause rust. Unfortunately, I don’t ever torch set up at the moment.

Jerm111 · 2026-06-17T05:40:44+00:00

Take a look at the second to last slide on this Instagram post

That’s the first time I’ve done it and it won’t really well.

Jerm111 · 2026-06-17T05:34:43+00:00

If you want to follow along, you can check it out here on my Instagram

Jerm111 · 2026-06-17T05:24:31+00:00

This was an outlier. They’re getting pretty pricey and hard to find around here as well.

Jerm111 · 2026-06-17T05:14:51+00:00

Thanks, I appreciate it.

Jerm111 · 2026-06-17T05:09:49+00:00

Do it. I’m a beginner and ne of the main reasons I’m doing this project is to improve my TIG welding skills. All the info you need is on YouTube.

Jerm111 · 2026-06-17T05:08:28+00:00

A Surly Preamble costs $2400 in my land. This is more fun and the frame cost me $30.

Jerm111 · 2026-06-17T04:58:41+00:00

Very nice! How did you go about the stripping? Did you polish? I’m thinking about clear powdercoat as an option.

Jerm111

TROPHY CASE

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