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SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

#1 2011-12-04 1:36pm

Frenchie Skyway
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From: Bordeaux France
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SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

Hi there,
I'm Philippe from France, this is my first and only one complete Bmx collector.
I'll try to do my best for my english / american language in this post.

When i was a kid i had a Skyway T/A always complete now and ready to rebuilt soon.
Skyway was my favorite brand, i think it was my first real design product incoming in my life.

Now i have 2 boys, they started Bmx race 2 years ago, i had this exciting idea 6 month after :

I took a BMX plus from my little magazines collection, i saw a kid with a white mini GT in the air across a double jump, i thought Skyway doesn't make a little Bmx frame for kids, in few seconds i'd got the idea : undersizing the frame with a more slopping top tube, find a mini brake, a mini Power lite bar, mini grips, mini number plate…etc….

And what kind of wheels ... ?
I had a really, really exciting idea !!
A fully handmade set of skyway 1"3/8, that was my goal.


Here the complete work step by step :

I found a white TA frame set in UK in normal condition with damaged brake bridge and drop out.
First i was thinking about the right method for changing the frame size.
The top tube length was good for me to compare with other junior frame size.
The rear triangle length was maybe a little bit to long but i was thinking it would be really hard
to change.
I decided to beginning the work myself, i will cut the top tube between the head tube and the seat tube
then seat tube to the rear triangle and bottom bracket, i found a dremel to do this job then, i thought i will find someone
to weld.
But i was really busy at work and after 3 months with no progress i found Malo on a french Bicycle forum to do the job completely.

He was really genius, he found the right solution quickly his skills are brilliant.
Please visit his web site to learn more about him and his new school production :
http://pir-bmx.com

Malo took every step in photo to explain and share the method, thank you very much to him.
Poor Malo, he's awaiting for this post for months !!!

....................................................................

THE FRAME


This is the plan i gave to Malo for started the work :


http://img841.imageshack.us/img841/1591/67149801.jpg



The original frame after cleaning


http://img845.imageshack.us/img845/8783/81101055.jpg
http://img220.imageshack.us/img220/8493/93915085.jpg



Step by step down sizing frame work



http://img259.imageshack.us/img259/2262/35223864.jpg
http://img854.imageshack.us/img854/1046/12684579.jpg
http://img845.imageshack.us/img845/5949/41200949.jpg
http://img267.imageshack.us/img267/6296/96393229.jpg
http://img267.imageshack.us/img267/6296/96393229.jpg
http://img836.imageshack.us/img836/4782/14176008.jpg
http://img832.imageshack.us/img832/2329/83876863.jpg
http://img215.imageshack.us/img215/8947/76851078.jpg
http://img845.imageshack.us/img845/9596/75147789.jpg
http://img11.imageshack.us/img11/8088/39170573.jpg
http://img696.imageshack.us/img696/1544/17729551.jpg
http://img546.imageshack.us/img546/6897/27997718.jpg
http://img20.imageshack.us/img20/4514/23458891.jpg
http://img215.imageshack.us/img215/2928/18839626.jpg
http://img820.imageshack.us/img820/5627/84995989.jpg
http://img577.imageshack.us/img577/9746/29705800.jpg
http://img855.imageshack.us/img855/2673/84226660.jpg
http://img708.imageshack.us/img708/729/24637180.jpg
http://img85.imageshack.us/img85/6681/44993055.jpg
http://img708.imageshack.us/img708/678/43439981.jpg
http://img39.imageshack.us/img39/4976/45407923.jpg
http://img220.imageshack.us/img220/1961/23647982.jpg
http://img853.imageshack.us/img853/5221/20211594.jpg
http://img259.imageshack.us/img259/1583/13336269.jpg
http://img689.imageshack.us/img689/7045/59284845.jpg
http://img33.imageshack.us/img33/8017/39601209.jpg
http://img819.imageshack.us/img819/7003/89409006.jpg
http://img43.imageshack.us/img43/9574/59246733.jpg
http://img194.imageshack.us/img194/6879/28222116.jpg
http://img215.imageshack.us/img215/8950/51378561.jpg
http://img804.imageshack.us/img804/3764/19330707.jpg
http://img39.imageshack.us/img39/5863/85157612.jpg
http://img805.imageshack.us/img805/9726/95588785.jpg
http://img7.imageshack.us/img7/9397/52159781.jpg
http://img854.imageshack.us/img854/2615/58142538.jpg
http://img823.imageshack.us/img823/3549/97018235.jpg
http://img440.imageshack.us/img440/1307/48472184.jpg
http://img850.imageshack.us/img850/6315/76056048.jpg
http://img259.imageshack.us/img259/2834/83874008.jpg
http://img856.imageshack.us/img856/7505/48992021.jpg
http://img706.imageshack.us/img706/9818/52535043.jpg
http://img823.imageshack.us/img823/9114/90869661.jpg



The complete work, really perfect !
Weld job is perfect, all details are fantastics, it look like a real Junior frame from Skyway factory.
Here you can compare between a 20" original size and the junior.


http://img716.imageshack.us/img716/3190/38587475.jpg
http://img577.imageshack.us/img577/4420/92607575.jpg


Frame (and fork) after powder coating.

http://img853.imageshack.us/img853/4821/98778745.jpg


The frame set ready to built with both NOS and restored parts.


http://img543.imageshack.us/img543/1259/44459984.jpg


Work in progress awaiting for the wheels


http://img43.imageshack.us/img43/8039/23583646.jpg



..........................................................................................


THE WHEELS, How to do ?



The idea is really simple :
All the elements of a Tuff Wheel can be turn or split into 27 flats plastic board parts and a cylinder for the hubs and the
valve hole.
After designed the Wheels i try to make a tool to cutting the plastic board but it was really hard to do, i gave the plan to an industrial company for cutting the 27 pieces in a chlorure de polyvinyle board (pvc).
All parts are in 3mm thikness.
For the hubs i found in a professional house ware 4 cylinders in almost the perfect size i just cutting 2 cm to reduce the height.

For the bonding i used a simple PVC adhesive, exactly the same for the PVC pipe you can use at home.


http://img851.imageshack.us/img851/5541/36378492.jpg
http://img846.imageshack.us/img846/1188/23086915.jpg
http://img14.imageshack.us/img14/7093/60782394.jpg



On one side of the Wheel i decided to engraved the logo and serial number like the Tuff Wheel II first generation graphites.
I don't have Graphites for model i only found some pictures as well.
Also my friend Arnaud (doublechevron in this forum) help me, he gave me 2 old Tuff Wheels, like that it was easy to imagine the future right shape for the 1" 3/8 size.



http://img543.imageshack.us/img543/8656/w48a.jpg
http://img854.imageshack.us/img854/7827/w45v.jpg
http://img543.imageshack.us/img543/8771/w46w.jpg
http://img4.imageshack.us/img4/6985/w49e.jpg
http://img840.imageshack.us/img840/9477/w410.jpg


I was looking for originals campy hubs to do a perfect job in accordance with engraved rims, in vain, i bought 2 aluminum complete loosing balls set NOS.


http://img440.imageshack.us/img440/9682/w411.jpg


After first step assembly (central star and all the slices for the rim part) i need to do the radius for the inside and outside edge of the rim. For the inside edge i use a car repair mastic, this is the classical method to do fine shape, i use also the same mastic to do all the curved shapes between all the stars and the rim and around the valve hole.


http://img163.imageshack.us/img163/839/98987446.jpg
http://img694.imageshack.us/img694/8309/10030838.jpg
http://img842.imageshack.us/img842/6286/w11sy.jpg
http://img831.imageshack.us/img831/8339/59345767.jpg
http://img31.imageshack.us/img31/9895/w12w.jpg
http://img11.imageshack.us/img11/4061/w13h.jpg
http://img703.imageshack.us/img703/8978/w14q.jpg


The 2 wheels was made with the same method, hours and hours do do well.


http://img809.imageshack.us/img809/8997/w15e.jpg
http://img713.imageshack.us/img713/3743/w16vm.jpg
http://img38.imageshack.us/img38/1469/w18i.jpg
http://img802.imageshack.us/img802/7350/w19o.jpg
http://img215.imageshack.us/img215/7633/w20p.jpg
http://img97.imageshack.us/img97/5789/w22x.jpg


First painting in glossy black. Glossy black reveals all the dents, pits,  PVC adhesive and mastic defaults.


http://img600.imageshack.us/img600/8778/w23oi.jpg
http://img197.imageshack.us/img197/8741/w25m.jpg


Again hours and hours to do as perfect as possible.


http://img13.imageshack.us/img13/4843/w26u.jpg
http://img51.imageshack.us/img51/558/w28l.jpg
http://img16.imageshack.us/img16/8876/w29k.jpg
http://img18.imageshack.us/img18/7183/w32i.jpg
http://img59.imageshack.us/img59/7412/w351.jpg
http://img440.imageshack.us/img440/2034/w33h.jpg
http://img714.imageshack.us/img714/6620/w34v.jpg



Final painting in mat black. Painting was made especially to reproduce graphite color as well.



http://img809.imageshack.us/img809/8833/w36v.jpg
http://img821.imageshack.us/img821/5982/w37ad.jpg
http://img38.imageshack.us/img38/1816/w38xe.jpg
http://img847.imageshack.us/img847/296/w42w.jpg




First complete built, some parts missing, flat tires and rear new school tire.

The frame can be use as a real little race bike, the wheels are really strongs i think a child can road gently with no problem, also they are a little bit lighter than a classic Tuff Wheel.
The front wheel is in great shape, turn straight and have no dent or pit, it almost perfect to do a mold.
The rear wheel have a little problem to spin straight is due to a problem during assembly but nothing serious.

Sorry for the last pictures, i'll make professionnal photos with a friend soon, but i couldn't wait more to share with you.

I'm looking for 2 Comp III or IV, i put a comp III in the front wheel but it's realy dry and i could not put the second
one on the rear wheel, even drier.
Please let me know if you have a NOS set to sale



http://img847.imageshack.us/img847/3479/dsc3820v.jpg






http://img100.imageshack.us/img100/9476/dsc3801u.jpg
http://img502.imageshack.us/img502/9241/dsc3808k.jpg
http://img193.imageshack.us/img193/4374/dsc3821qk.jpg
http://img221.imageshack.us/img221/1364/dsc3822luhh.jpg


Close view




http://img59.imageshack.us/img59/317/dsc3825a.jpg
http://img28.imageshack.us/img28/3069/dsc3826.jpg
http://img855.imageshack.us/img855/8984/dsc3844k.jpg
http://img440.imageshack.us/img440/6937/dsc3847r.jpg
http://img37.imageshack.us/img37/9950/dsc2803m.jpg
http://img191.imageshack.us/img191/4862/dsc3837f.jpg
http://img853.imageshack.us/img853/3620/dsc3839k.jpg
http://img403.imageshack.us/img403/4365/dsc3853w.jpg
http://img221.imageshack.us/img221/2418/dsc3858e.jpg
http://img41.imageshack.us/img41/5385/dsc3862t.jpg


I'm really happy to share this project with you,
i'd like to many thanks to :
Malo, thank you for your skills
Arnaud, thank you for your help
Jeff Haney, thank you for your enthusiasts pm last week.
Roller in line (cutting and engraved PVC)
Atelier Stephane (painter)


My next built would be an other Junior frame in chrome finish with Euro bottom bracket.
You bet ?

I hope the folks from Skyway would appreciate my job, i have tons of ideas for them !!
;-)
Cheers.

.......................................................................

Junior TA frame, original TA fork.
Revcore drop out saver (not show)
165mm Terry crank (from Rod Miles skyway pit bike)
Sugino bolts and 40 teeth ring
Mini Hutch pedals TI axle
Izumi chain (with holes in both sides of each link, don't know the name of this product)
Suntour,Free wheel.
First generation Hutch seat clamp
Uni mini seat with cover (i have 2 UNI, one with right tube diameter and small seat and one with smaller
tube for mini frame, the frame keep the "normal size")
Mini Dia compe brake  (thank you Arnaud ;-)) with Skyway pro pad.
Shimano SX lever
AME dual mini grips
GT epoch head set.
Mini Powerlite handle bar or Mid size Powerlite handle bar for an "expert" built
Pro Neck mini stem
Mini serie number plate (can't decide myself to open the bag…)
Looking for a NOS set of comp III or IV

All NOS parts except Terry crank and mid size powerlite handle bar. (not show)


Ready for Rockford 2012 ?
;-)

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#2 2011-12-04 1:43pm

erdalicious
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

coolcoolcoolcool

but too many pichers!!!!!


WTB: * NOS Oakley F1 grips black/yellow * KKT FMX/LMX Pedals * Skyway Tuff Graphite pedals/cages * NOS Oakley 2 red right side only * NOS Oakley 1 red left side only * NOS chrome KKT FMX left side pedal 9/16

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#3 2011-12-04 1:45pm

Porkchopzz4
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

WOW! This is one of the coolest things I've ever seen. Awesome idea and execution! big_smile

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#4 2011-12-04 1:46pm

Haro-83
Pro MemberTEXAS HILLBILLY
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

Impressive! yikes  now do the 26" big_smile


Build it, Ride it & Break it. That what "it" was made for.

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#5 2011-12-04 1:47pm

thesega
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

WOW, This thread is pretty cool!


I always hated when people Split the F/F. The Fork goes to that frame So why split it?
true ballers only ride proto-types
"This show is stupid, Turn it up louder"
jimmybills: 'costco broke my glove box'

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#6 2011-12-04 1:49pm

STOLEN85TRICKSTAR
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

Over the top!


D34l4life

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#7 2011-12-04 1:52pm

wfc09
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

yikes WOW!

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#8 2011-12-04 1:53pm

erdalicious
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

what size are the tires?

20 X 1 3/8"??

t'as fait une bonne travail la bas!!!!


WTB: * NOS Oakley F1 grips black/yellow * KKT FMX/LMX Pedals * Skyway Tuff Graphite pedals/cages * NOS Oakley 2 red right side only * NOS Oakley 1 red left side only * NOS chrome KKT FMX left side pedal 9/16

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#9 2011-12-04 2:02pm

pcmcobra
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

NICE!!!!!!smile


A village in Kenya is missing an idiot

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#10 2011-12-04 2:03pm

Neil-Son
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

DO A HUTCHHHHHHHHHHHHHHHHHH !!!!!!!     big_smile

Vous avez fait un travail fantastique sur qui construisent

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#11 2011-12-04 2:12pm

Iceman
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

cool


neither was any thing ells are government gave away simi free. that's why this country's broke and six trillion dollars in det already.

so what if they make the hole a little more deeper hole. ether way were screwed. but for now some are kinda happy.

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#12 2011-12-04 2:14pm

shaved_ape
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

Are those wheels really going to be that strong?

Wouldn't they be stronger if you used those originals to make a mold so it is one solid piece?


WTB: Knight Sith Handlebars.  Blue knight retro stem.

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#13 2011-12-04 2:14pm

erdalicious
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

Neil-Son wrote:

DO A HUTCHHHHHHHHHHHHHHHHHH !!!!!!!     big_smile

Vous avez fait un travail fantastique sur qui construisent

yikesyikesyikes
didn't know you speak French too Son!!!!
































vive google translator big_smilebig_smilebig_smilebig_smile

lollollollollollol


WTB: * NOS Oakley F1 grips black/yellow * KKT FMX/LMX Pedals * Skyway Tuff Graphite pedals/cages * NOS Oakley 2 red right side only * NOS Oakley 1 red left side only * NOS chrome KKT FMX left side pedal 9/16

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#14 2011-12-04 2:23pm

Neil-Son
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

erdalicious wrote:

Neil-Son wrote:

DO A HUTCHHHHHHHHHHHHHHHHHH !!!!!!!     big_smile

Vous avez fait un travail fantastique sur qui construisent

yikesyikesyikes
didn't know you speak French too Son!!!!



�� � �� �らゆる言語� �兄弟を話� �� �� �� �� ��  � �� �。� �� �� �� �� �父マイクを�� � �� �る� �� �� �� ��  � �� �      big_smile



























vive google translator big_smilebig_smilebig_smilebig_smile

lollollollollollol

�� � �� �らゆる言語� �兄弟を話� �� �� �� �� ��  � �� �。� �� �� �� �� �父マイクを�� � �� �る� �� �� �� ��  � �� �      big_smile

Last edited by Neil-Son (2011-12-04 2:24pm)

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#15 2011-12-04 2:24pm

bird
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

that is some real awesome work.   i would hire ya to do a build like that for me.


44T CHICAGO CLUB RIDER
WANTED::::anything reynolds racing
WANTED::::bandito jersey
WANTED::::yellow panaracer tire 1 1/8
WANTED::::jmc pit bike
WANTED::::less talk,more riding

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#16 2011-12-04 2:27pm

Neil-Son
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

shaved_ape wrote:

Are those wheels really going to be that strong?

Wouldn't they be stronger if you used those originals to make a mold so it is one solid piece?

I was wondering that myself but it seems that its going to be a show bike only. I can see these wheels being produced by tuf in the future

First it was raskas project now this..just amazing..E-Rad show us what you got ..youre european tongue


btw Phillipe, you mentioned that youre going to have a professional take pics of the bike. Would it be too much to ask if you have a scantily clad french chick in that photo shoot too ?  big_smile


4-8 would be nice

Last edited by Neil-Son (2011-12-04 2:34pm)

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#17 2011-12-04 2:33pm

shaved_ape
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

Neil-Son wrote:

shaved_ape wrote:

Are those wheels really going to be that strong?

Wouldn't they be stronger if you used those originals to make a mold so it is one solid piece?

I was wondering that myself but it seems that its going to be a show bike only. I can see these wheels being produced by tuf in the future

First it was raskas project now this..just amazing..E-Rad show us what you got ..youre european tongue

I don't know if mini's are popular enough to do those.

26" tuffs would be cool to see, but I don't know that they would hold up structurally.  Maybe if they had 8 spokes or something but I doubt it.


WTB: Knight Sith Handlebars.  Blue knight retro stem.

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#18 2011-12-04 2:39pm

Neil-Son
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

shaved_ape wrote:

Neil-Son wrote:

shaved_ape wrote:

Are those wheels really going to be that strong?

Wouldn't they be stronger if you used those originals to make a mold so it is one solid piece?

I was wondering that myself but it seems that its going to be a show bike only. I can see these wheels being produced by tuf in the future

First it was raskas project now this..just amazing..E-Rad show us what you got ..youre european tongue

I don't know if mini's are popular enough to do those.

26" tuffs would be cool to see, but I don't know that they would hold up structurally.  Maybe if they had 8 spokes or something but I doubt it.

gotta put them wheels to the test but I think it would hold for straight riding by a kid under 75 lbs maybe

Last edited by Neil-Son (2011-12-04 2:40pm)

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#19 2011-12-04 3:14pm

Rastacosta
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From: Springfield, MA
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

this is the most incredible build i have ever seen & great explanation of the process that went in to the build a 26" would b nice 2 keep up the great wrk


Luv My Toys I'm a Kid At Heart Cars, Bikes, Electronics, Skiing, Boarding {snow&skate}, Golf, RC Cars, & What Ever Else Can b FUN!!! You Only Live Once Live Every Day Like it's Your Last!!! "NO REGRETS=NO REWARD"  "NO $  NO big_smile "

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#20 2011-12-04 3:33pm

ivegotabike
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

Tabernac!!!! Over the top! RAD!!!


My next bike will be my LAST one.

In a closed society where everybody's guilty, the only crime is getting caught. In a world of thieves, the only final sin is stupidity.
Hunter S. Thompson

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#21 2011-12-04 4:59pm

thewhitelarrybird
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

yikesyikesyikes

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#22 2011-12-04 7:31pm

midschooler
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From: Joliet, IL
Signed up: 2010-01-11
Posts: 1756
Bikes: 47
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

Too cool. Well done.


I pick up what you throw out                                                                                                          Lookin for uncut blast bars!!!!!!!!!!!
O.G.O.A.R.                                                                                                                                                                Midwest BMX

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#23 2011-12-04 7:53pm

Jonz44
Museum Addict
From: Kentucky
Signed up: 2011-06-18
Posts: 1251
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

Cool build,  great work on the frame and Tuff's


Skyway Fan!!
Ready to build my Skyway 24's!!!

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#24 2011-12-04 9:05pm

Brickos
Banned
From: Sydney, Australia
Signed up: 2010-02-15
Posts: 137
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

holy F**K


*** ELF forks 24inch ***

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#25 2011-12-04 9:18pm

Ladis
Museum Addict
From: Germany
Signed up: 2007-12-18
Posts: 1278
Bikes: 2
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Re: SKYWAY T/A JUNIOR with 1"3/8 TUFF WHEELS

That´s what I call dedication.....smile

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