Frame Building with Bilenky.

Stephen Bilenky the man behind the award-winning frames of Bilenky Cycle Works recently returned to Metal Guru to teach a Fillet Brazed Frame Building Class to two eager students. With 30 years of professional frame building experience, Stephen is extremely knowledgeable on the subject. He also has an excellent wit and sense of humor and his lectures were informative and technical but still engaging.

Scott Schofield of Indigo Custom Bicycles who builds custom lugged frames enrolled in the class so he could refine his techniques in fillet brazed construction to better serve customers that might require a specific geometry and tubing diameters that lugged construction methods might not be able to produce. Scott chose to build a sloping top tube cyclo-cross frame with a roomy 32+ tire clearance, an oversize tube set, rim brakes and S-bend rear stays.

Chris H. built a custom sized road frame for his wife with a geometry suited to long distance riding. Due to her smaller stature Chris decided to use 26″ diameter rims rather than either 650c or 700c. Chris decided to go with a tube set with traditional tubing diameters to keep the ride feel compliant and chose to use straight rear stays for the simple clean aesthetic.

The following gallery shows their progress through the class.

A student list already forming for another class, please email or call (845)883-4303 ext. 2 if you are interested. A description of the class details can be found here.

Thanks for everything Stephen. Great work Chris and Scott!


click on any photo for caption and to begin slide show.

Silent welds.

Justin Shipp builds lugged bicycle frames in Chattanooga, Tennessee. His bicycle company is named Silent Cycles. Silent Cycles

Justin attended Metal Guru to learn the process of TIG welding bicycle frames. He arrived in style in a 1981 Mercedes turbo diesel station wagon converted to use waste vegetable oil as a fuel source.

Justin’s prior frame building experience gave him both the manual dexterity and attention to detail necessary to quickly master the bicycle frame welding process. He chose to build a ‘monster’ cyclo-cross frame in class that has disc brake mounts, clearance for a triple chain ring crank, a suspension corrected geometry and can fit full size 29″ tires.

Below is an extensive gallery that details Justin’s progress through the class and also a few photos of his wagon.

Excellent work Justin!!


Black Trumpet.

Aaron W. chose a type of wild mushroom that he found while foraging in the woods near his home for the name of his new cyclo-cross disc frame, Black Trumpet. Here are some photos of the frame after paint and the complete bicycle on it’s inaugural ride.


A detail shot of the head badge in it’s native habitat.

The complete bicycle in the woods.

Every Picture Tells a Story.

With hard work, perseverance, and practice Aaron W. has created his first bicycle frame. It is a cyclo-cross disc frame and the results of his hard work and determination speak for themselves.

In this gallery are some photos that capture the progress he made through the Metal Guru frame building class. Great job Aaron!


Another new frame.

Here are some shots of a continuing student with a good eye for detail and the new CX disc frame he just finished. Very well done Brett!