So far there's only been one unanticipated modification: my first cut, where the seat tube meets the bottom bracket, was severely offset because I had naively assumed the mitering bracket was level with the hole saw. To make it work, I had to make the seat tube shorter than it should be. It should still be stable.
My biggest worry now: how level is the head tube and bottom bracket going to be?
stays remain before it is JB Weld time!
Before this kit came in, I didn't even know "miter" was a word. Predictably, my first cut went very poorly (the bracket does not align the piece vertically!), so my seat tube is 1-2cm shorter than it should be. I'm so paranoid of screwing up further, that it takes forever: each 5 minutes of video is easily an hour and a half of my time. It doesn't help that the videos diverge from the parts sent on occasion: the video doesn't take into account bent seat stays, and the ridges on the dropouts are on the opposite side than the video. Bending the aluminum parts is much harder than the video makes it look: I'm currently on crutches and have to get a friend to help out on those bits, and even he struggled on the first one.
Following the video can be very frustrating, as attention to details is pretty key: Craig does not walk you through everything, but instead assumes that you are paying full attention at all times. For example, in the seat stays portion, one of the seat stays is magically cut in between frames: follow along, young whippersnapper! Overall, it's easily the most fun I've ever had in my garage.
If Calfee really wanted to make this user-friendly, they'd take a blithering idiot like me, see all the head-scratching moments, and use it to improve the video. Instead, I think the difficulty will likely remain the cost of entry. I am extremely skeptical at this point that my frame will be level and symmetric enough to be a good ride. A wee bit of hope remains, however. I went a bit overboard on buying components for the build, so I've got an investment to protect at this point.
The robots have come to save us, basically.
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