Fabricating the headtubes

One of the first hurdles I encountered was that Genesis Super 32’s frame was made of aluminum, which meant I could not weld it. [The welder I use can only weld steel.]

This presented a challenge in that I could no longer use the Genesis Super 32’s head tubes, which I totally needed because of the unique size of the Super 32’s head tube — it was quite large; both in diameter and length. And nothing in my stockpile of bike frames would fit the Super 32’s bearing cups and fork.


Next I thought I would simply cut a piece of steel pipe to the appropriate length. Unfortunately none of the pieces of steel pipe that I had in my materials bin had the appropriate inside diameter to seat the bearing cups. The picture below shows that I got close with a piece of 1.5″ EMT conduit, alas not close enough.


So it was off to the hardware store; bearing cup and magnet in hand. …bearing cup to make sure the found item was the correct size; and magnet to make sure the found item was steel.

After a little digging around I found a coupling for 1.5″ EMT conduit that fit the bearing cups nicely. [See an EMT 1-1/2 in. Set Screw Coupling from Home Depot pictured below].


Unfortunately, off the shelf, the coupling was too short for the fork’s length. [See the coupling matched against the Super 32’s head tube pictured below.]


Not a problem. I would simply cut the coupling in half and then extend it appropriately with a piece of 1.5″ EMT conduit and weld the whole thing together.


The coupling made this task easy in that it had a grove in the center offering the perfect cutting guide, as well as set screws to hold the conduit in place during welding.


Pictured below is the homemade steering tube assembled (pre-weld) with bearing cups and bearings mounted onto a Genesis Super 32 fork.


It was as though the little coupling was destined to become a head tube. Pictured below are two homemade head tubes.


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