Diamond Frame Chopping - Page 1 of 21

Figure 1

This basic tutorial will guide you through the process of cutting up a typical diamond shaped bicycle frame into its individual tubes and components so that you can re-use these parts in your own designs. A diamond frame is made up of a front and rear triangle, forming a diamond shape. The round steel tubing on a bicycle frame ranges in diameter from 3/4 inch to over 2 inches in diameter depending on the style of the frame.

Figure 2

Three different types of grinder discs will be used when cutting up the steel tube bicycle frame: a standard coarse grinding disc for rough metal cleanup (center); a thin zip disc for cutting the tubing; and a sanding disc for final cleanup of the tubing and removal of paint. All grinder discs should be the proper size for your grinder as indicated in your owner's manual. Along with an angle grinder, you will need the usual safety gear: eye protection, hearing protection, and work gloves. A full face shield in front of your safety glasses will give you optimal protection when grinding metal.

Figure 3

The cutting disc (also known as a "zip disc") is a very thin grinder disc that can quickly cut through hollow steel tubing of various diameters. Round tubing as well as square tubing can easily be cut by the zip disc, although a hacksaw can also be used if you don't mind the added effort. The zip disc used in this tutorial is a 5 inch diameter disc with a 3/64 inch thickness.

Figure 4

A sanding disc is also known as a "flap disc" because it is made up of many overlapping flaps of sandpaper, and can remove metal as well as paint and stickers from bicycle tubing. A flap disc is usually used for final cleanup or when you are grinding a weld flush to the surround material. Because a flap disc does not remove metal as quickly as a rough grinder disc, it is much better for grinding an area where only a small amount of material should be removed.

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You can build it yourself from our easy to follow DIY plans!