Jann’s First Bike of His Own

Jann has been riding the same trekking bike for more than 30 years.

He bought it as a young man in Braunschweig. Over the years, he repaired plenty of things himself, had other things repaired, and simply kept riding it.

Eventually, though, it started to show its age. A little rust here and there, and visually it had seen better days.

Originally, Jann wanted to restore it completely.

Then his partner needed a new bicycle.

And while browsing online, Jann came across a photo of an all-terrain bike from a small bicycle manufacturer in the UK.

That changed the plan.

He no longer wanted to simply restore his old bicycle.

He wanted to build two bicycles himself. One for him and one for his partner.

But How Do You Build a Bicycle Frame at Home?

Jann is 57, originally from Hamburg, and now lives with his partner in Ellerau, near Quickborn.

He is a master refrigeration technician, so he already had experience working with metal and brazing pipes. Since 2019, however, he has spent most of his working life in an office, providing service and support for a large German refrigeration company in Hamburg.

As the idea of building the two bicycles became more serious, he started looking for a framebuilding course in Germany and eventually found my website.

Taking a course with me in Potsdam wasn’t really an option for him at the time. It didn’t make sense financially or in terms of time.

But when we first got in touch, another possibility came up.

I was just about to start my first Online Framebuilding Course.

Jann signed up.

And things started moving.

First, Build a Workshop

During the first online meetings, Jann got to know the other participants.

We covered the workshop equipment they would need, the fundamentals of framebuilding and the different materials.

Then Jann first had to create what he needed to build a frame at home.

He put together and built his own frame jig.

After that, he found the frame tubes and other materials he needed online.

Up to this point, things were going pretty well.

Then came BikeCAD.

“I Thought This Probably Wasn’t Going to Work.”

Jann was supposed to use BikeCAD to plan his frame.

That didn’t go particularly well.

Actually, it didn’t go well at all.

“I still can’t use it…!!!”

While some of the other participants were already much further along with their designs, Jann felt like he was falling behind.

“At the time, I thought this probably wasn’t going to work…”

So he needed another solution.

Instead of designing his frame completely from scratch on the computer, he used the geometry of his old bicycle as a starting point and modified it for the new bike.

That was enough.

He could start building.

What Do You Actually Need to Build a Frame at Home?

Jann had far fewer concerns about the hands-on part.

After all, working with metal and brazing pipes are part of his professional background.

But I think his assessment of what you actually need to build a bicycle frame at home is interesting:

“Basically, a frame jig, files, a tube cutter, a hacksaw, a propane/oxygen torch, sandpaper and a bit of perseverance are enough to build the frame by following the online course.”

And, of course, you need someone to show you what to do with all of it.

Jann worked his way through the individual stages of building the frame, using the videos, my explanations and our live online meetings to guide him.

And I got to learn something from him as well.

Because of his professional experience, Jann took over part of our brazing safety instruction.

That turned the course into something I’d hoped it would become: not simply me teaching a group, but a group of people with different backgrounds and experience who could also learn from one another.

And Then He Just Kept Building

There was one point where I advised Jann against an idea.

He didn’t only want to build the frame himself.

He wanted to build the fork too.

And the handlebar.

And the rack.

I thought the frame was probably enough for a first project.

Jann apparently didn’t.

After doing some research online, he built the fork, handlebar and rack himself as well.

And while he was at it:

Of course he built his own wheels too.

The Moment of Truth

Eventually, Jann’s first frame stood finished in his workshop.

And he was surprised.

“I was surprised that the first frame was so straight and solid. I had expected to have to do much more alignment.”

Then the parts went off to be painted.

When they came back, Jann could finally assemble the bicycle.

That wasn’t completely trouble-free either. The drivetrain in particular caused some difficulties.

From the beginning of the project to the finished bicycle took about a year.

Then it was ready.

Jann got onto the bicycle he’d built himself.

And rode away.

Riding Through Town With His Heart Pounding

Jann describes those first kilometers like this:

“It was absolutely exhilarating to ride those first kilometers after getting on the bike and riding away for the first time.”

He rode through town with his heart pounding.

Not on a bicycle he’d bought somewhere.

In front of him were a frame, fork, handlebar, rack and wheels that hadn’t even existed a few months earlier.

Now they had become a bicycle.

His bicycle. Built in his own basement workshop.

Since then, Jann has taken the bike to Boltenhagen as well. When they go away for a short holiday and take their bicycles with them, his self-built bike comes along.

It Probably Won’t Be the Last

The whole story actually started with Jann’s old trekking bike.

The bicycle he’s owned for more than 30 years and originally planned to restore.

There’s now a new plan for that one too.

It’s going to become a cargo bike.

And then, of course, there’s the second bicycle that helped start this whole idea in the first place.

He still needs to build the bike for his partner.

Apparently those aren’t the only projects Jann now has in mind either.

“I think there will be more DIY bikes to come…”

There’s just one small problem.

First, Jann needs to clean up his basement workshop. 😅