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PostPosted: Sat Dec 25, 2010 12:15 am 
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Carbon Cowboy
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Joined: Sat Sep 04, 2010 7:20 pm
Posts: 975
Location: Slovenia
Hi!

Just a quick introduction:
I'm 18 (and a half) years old and an U23 Continental cyclist from Slovenia (Europe). Beside of cycling my big passion is also making carbon fibre components. My dream is to succeed as a pro cyclist or (if not as a pro cyclist) I would love to have my own company some day...



Here are just a few products, handmade by me:
Image
142g saddle&setpost combo

Image
128g seatpost 31.6mm x 275mm (also all the ALU work is handmade by myself)

Image
Shimano Ultegra "brake cap"

etc.,...



Image
Berk PROTO-TYPE 2 frame SUB 1180g
and it's topic: http://fairwheelbikes.com/forum/viewtop ... f=6&t=7194

Unfortunately I don't have a lot of time for the carbon work (I train a lot, education, girlfriend,.. :wink: ), but I really love the work and will for sure continue making some new custom components and of course test/ride them.



My symbol is ..., and Berk is my surename.







This topic is about a new frame. A birth of a new frame, called PROTO-TYPE 3.

I already made 2 frames and some other components...the second frame (topic "Berk PROTO-TYPE 2") was really a big success for me.

But I want to make it even better! It's sure possible, so that is also the reason that I'll make another road frame. I already know how to improve a few details and reduce the weight of the frame, with good stiffness! My aim is SUB 1000g.

Everything is handmade by myself.



Berk PROTO-TYPE 3

Scheme of the frame:
Image
Just to let you know what's already made...



Image
Downtube...

...the inside:
Image



Will post more photos and news soon...

Hope you'll like it - any comments etc. are welcome!
Thanks for your attention :thumbup:

_________________
Berk PROTO-TYPE Composites - Handmade In Slovenia
Berk Composites
http://www.berk-composites.com/
info(a)berk-composites.com


Last edited by Berk on Thu Sep 29, 2011 5:33 pm, edited 5 times in total.

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Posted: Sat Dec 25, 2010 12:15 am 


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sat Dec 25, 2010 3:27 am 
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Joined: Thu Nov 10, 2005 5:31 pm
Posts: 3461
Location: Surrey B.C. Canada
I have followed all of your builds and components that you have build and was wondering if Proto-Type 3 will incorporate a few of the items together. A sub 1000g frame will be the lightest you have build but is not super light. I was thinking since you know your saddle height very well at this point coming from a builder/racer background that you could probably build the saddle onto the ISP and save a lot of weight not having any mounting hardward for the post. You saddle/post combo is pretty light but imagine how much weight you could save if you built everything together. Just a thought.

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AERO & LIGHT is RIGHT

Cervelo SLC 5960g/13.13 lbs


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sat Dec 25, 2010 5:58 am 
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Joined: Sat May 09, 2009 6:23 pm
Posts: 45
Location: Bay Area, CA
I really enjoyed your previous build threads and am looking forward to this one. Even more details about the assembly techniques would be appreciated.

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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sat Dec 25, 2010 9:37 am 
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Carbon Cowboy
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Joined: Sat Sep 04, 2010 7:20 pm
Posts: 975
Location: Slovenia
First of all thanks!

BmanX wrote:
/...I was thinking since you know your saddle height very well at this point coming from a builder/racer background that you could probably build the saddle onto the ISP and save a lot of weight not having any mounting hardward for the post. You saddle/post combo is pretty light but imagine how much weight you could save if you built everything together. Just a thought.


I know what you mean and I already though about this,...it would be really the lightest way to build a bike. I would save cca. 200g !?! (the carbon saddle weights less than 60g + reinforcements, Ritchey stubby and SLR saddle = +250g). Will think about it - if I would like to use a stubby, I could still just cut the end of the seatpost with the integrated saddle,...and If I cut the ISP I can stll use a 31.6mm seatpost,...quite a lot of options :mrgreen:. Will see... But most of the time I'll have to ride my sponsor bike (Wilier, Sram Red,..), and it's nice to borrow the bike that I made for a test ride to my friends. I have just a Sram Rival groupset with Sram S900 crank, not really WW, but good enough for the test ride :mrgreen:

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Berk PROTO-TYPE Composites - Handmade In Slovenia
Berk Composites
http://www.berk-composites.com/
info(a)berk-composites.com


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sat Dec 25, 2010 10:34 am 
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Joined: Thu May 18, 2006 5:20 pm
Posts: 977
Location: Cyprus
I also followed all your work and prototypes... really nice work and craftsmanship ... well done.

I was with the impression that the new Prototype 3 would be a TT frame ... :) a WW is also welcomed ... keep up the good work!!

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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sat Dec 25, 2010 11:18 am 
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Carbon Cowboy
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Joined: Sat Sep 04, 2010 7:20 pm
Posts: 975
Location: Slovenia
Thanks!

Yes, I'm also already working on a TT frame, but for now only on paper...and yes, I will make one for sure! Will see about my free time, most likely during the summer.

This frame (PROTO-TYPE 3) won't take me a lot of work time. Tomorrow I'll go on a training camp with my team (till 30 December) and after that I'll continue with the work. I already made the moulds for the tubes at the end of the season, and most of the tubes for this frame are already done!


I'll use the same tube for the headtube and the downtube. The inside diameter is 44mm (for press-fit headsets) and the outside diameter is 47mm.


Image
105cm of the tube

Image
265g and 105cm




Mention that the tube is still rough, without any work on the surface jet:
Image

Image



And of course I had to cut the tube:
Image


Headtube:
Image
160mm

Downtube:
Image

I still have to precise cut the end of the tube and of course shape it (right angle and "groove"), that it will fit perfectly when I'll glue the tubes together... At the end the downtube should weight just under 160g.




Also the BB will be for press-fit bearings (41mm), carbon fibre tube, 86.5mm wide.

Will keep you updated. If possible also during my training-camp, because I already have "some news in stock" :wink:

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Berk PROTO-TYPE Composites - Handmade In Slovenia
Berk Composites
http://www.berk-composites.com/
info(a)berk-composites.com


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sat Dec 25, 2010 2:08 pm 
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Joined: Mon Apr 30, 2007 11:02 pm
Posts: 1152
Location: around amsterdam
very nice to see this
this must take a lot of patience

i just weighed my ax endurance saddle and my deadelus seatpost (longest version) and together they are 209 grams
its nice to see that i could shave of about 50 grams with combination setup

cheers

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a light bike does make you go faster unless you are slow


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sat Dec 25, 2010 7:37 pm 
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Posts: 351
I think you have a brilliant talent as a designer, craftsman and fabricator. Maybe you should start your own company or a consulting firm regardless of whatever else you choose to pursue as a career!


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sat Dec 25, 2010 8:33 pm 
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Location: Vicenza
Another great topic to follow. :thumbup:

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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sat Dec 25, 2010 11:01 pm 
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Carbon Cowboy
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Joined: Sat Sep 04, 2010 7:20 pm
Posts: 975
Location: Slovenia
tochnics wrote:
...this must take a lot of patience


...yes indeed :mrgreen: but it's a really great work, I love it, you can really build your own dream bike...and with any new component you learn a lot, and every next product is better, etc.,...

@micky
I'm glad that you like it!


@kac
That would be really a dream job for me! Hopefully some day I'll manage to have my own small company. I have a lot of new ideas and innovations how I can make new components, I'm just waiting to have some free time to make the projects true.

I have an A4 notebook with already 37 pages how I'll make some new carbon components and experiments! All the "lamination-plans", schemes (for almost every component - stem, brakes,...), experiments that I have to do,...but unfortunately it's my secret and I'm the only one who knows how exactly I make it. Most of people thought that it's impossible when I started to making the first frame,...and when I made the first and the second frame, I start with new projects on the paper,...one of them is also PROTO-TYPE 3, but beside the new frame there is also a plan how I would make my own wheelset etc.,.. Most of people again said that it's impossible,...but I don't think so... :mrgreen: I just need some time, and some day I'll sure try to make the most ultimate projects...but for now step by step, a lot of testing etc., and slowly I'll be prepared for new, better projects... :mrgreen:


This time I choose another road frame (although I don't need it), because I can learn a lot during this project. My aim is SUB 1000g, maybe even less...will see! It may last for a few months, but I hope that you'll enjoy those projects...of course I'll keep you updated & thanks for your attention :thumbup:

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Berk PROTO-TYPE Composites - Handmade In Slovenia
Berk Composites
http://www.berk-composites.com/
info(a)berk-composites.com


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sun Dec 26, 2010 3:13 am 
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Joined: Sun Oct 03, 2010 8:36 pm
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Location: Holland, Meppel
Cool! A Berk project again.
I'm going to follow this for sure!

:thumbup:


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Sun Dec 26, 2010 9:35 pm 
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Carbon Cowboy
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Joined: Sat Sep 04, 2010 7:20 pm
Posts: 975
Location: Slovenia
:D



Chainstays

Image

17mm x 14.5mm

Image

Image
490mm each, so I'll still have to cut them. The surface is still rough,...

Image


This is it for today! Greetings from Pokljuka (Slovenia) where I have a training-camp with my team (till Friday). On 19.12 there was the biathlon world cup and it's really great to train here!

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Berk PROTO-TYPE Composites - Handmade In Slovenia
Berk Composites
http://www.berk-composites.com/
info(a)berk-composites.com


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Mon Dec 27, 2010 8:07 pm 
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Carbon Cowboy
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Joined: Sat Sep 04, 2010 7:20 pm
Posts: 975
Location: Slovenia
Bottom bracket - BB

Carbon fibre BB for press-fit bearings (41mm).

Just the base tube, after the joint will be reinforced the tube should be cca. 3.5mm thick.


BB with Truvativ bearing (for Sram crankset)
Image

It's really very tight, just like it should be (with hands it's "impossible" to insert the bearing, but with a little bit help it's just perfect!)
Image


When I'll come home I'll still have quite a lot of work to do...just can't wait!


Still quite a lot of work to do,...
Image

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Berk PROTO-TYPE Composites - Handmade In Slovenia
Berk Composites
http://www.berk-composites.com/
info(a)berk-composites.com


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Mon Dec 27, 2010 8:25 pm 
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Joined: Thu Nov 10, 2005 5:31 pm
Posts: 3461
Location: Surrey B.C. Canada
AWESOME just incredible work. I love your threads and would be honoured one day to own a bike from you.

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BIG DADDY B FLOW
AERO & LIGHT is RIGHT

Cervelo SLC 5960g/13.13 lbs


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 Post subject: Re: Berk PROTO-TYPE 3
Posted: Mon Dec 27, 2010 8:25 pm 


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 Post subject: Re: Berk PROTO-TYPE 3
PostPosted: Mon Dec 27, 2010 10:13 pm 
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Location: San Francisco, CA
Subscribed!

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2011 Specialized S-Works Tarmac SL3 (If the insurance allows)
2010 Specialized Tarmac Pro
2008 Custom Columbus XLR8R Frame (Team Branded)
2006 Specialized S-Works E5 Aerotec - Stolen
1995 Pinarello Stelvio (Fixed Gear)


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