PVD 5.5" Fork Hardtail Aluminum

This is going to be my first aluminum bike, so I have a few details to work out.

Geometry

Tubeset

Easton Ultra-Lite 7005 Taperwall MTB tubeset

• Down Tube - 429351
• Top Tube - 329375
• Seat Tube - 129338
• Chain Stay - S-Bend, 045715
• Seat Stay - 12° bend??, 529548

7005 Aluminum Stock

This tubing is widely available as special bicycle tubing, but is rare to find as bulk straight gauge tube. ASTM B221 Pertains to 7005(T53)(UNS A97005, #27)Aluminum in Bar Tube and Wire

ISO	France NF	USA ASTM	German DIN	UK BS	Italy UNI	Switzerland VSM	Sweden IS	Japan JIS
ALZn4,5Mg1	7020	(7005)	AlZn4,5Mg1 3.4335	H17 7020	7791	AlZn4,5Mg1	4425

One source is Fairing, Full 2008 Catalog

• Reynolds 7005, Fairing
• Reynolds
• Columbus Aluminum
• Dedacciai
• Dedacciai - Bringheli
• Asia Metal Solutions

• Alcoa 7020
• EMJ 2" 7005

Odd Parts

Ahrens is selling some quality parts, the dropouts look very nice.

Head Tube and Headset

Custom Head tube

Cane Creek ZS-2

• Upper Stack - 8mm
• Lower Stack - 5.6mm

Fabrication Instructions

Easton Fabrication Instructions 7005 & 6061

Welding Practice

• Miller - JOINING ALUMINUM WITH GTAW
• Miller's Guideline to Gas Tungsten Arc Welding (GTAW) Handbook

Welding Rod

"Use 5356, 5180 or 5183 fillers for welding 7005 frames.", Easton. "5356/5180/5183" Columbus

"Al Mg Si 05 (USA 6063) - CASTO MAG 45802" CeeWay.

Ageing - Heat Treating

Columbus

Frames in 7000 alloy.
The ageing of the frame realized in 7000 alloy has to be carried out 4/5 days after the welding, in two phases: 6 hours at 90°C ±5° - 4 hours at 150°C ±5°.

Easton

Artificial age for 7005 frames:
Age 6 hours at 200 degrees F (± 10 degrees F) plus 4 hours at 320 degrees F (±10 degrees F). This process must be performed by the builder on all Easton 7005 tube sets.