Inside The Seat Tube After Line Boring

It is always hard to get a nice photo of the inside of a tube, but the sun was just right and I thought I would give it a try. A perfect diameter seat tube is important for the seat post to work smoothly, and to protect carbon posts from getting damaged from any welding distortion.

Customers Ask Great Questions!

This is what the BB and seat tube look like before it goes back in the frame fixture for final assembly and welding. Notice that the BB and seat tube are fusion and completely welded before the down tube blocks access to the entire BB , seat tube joint. Hope this is helpful!

No Reaming Here!

Titanium does not like to be reamed! This is a good shot of the seat tube being machine line bored, a timely process that leaves the seat tube with a beautiful 360 degree, 100 % fully machined surface for a perfect seat post fit!

Line Boring Seat Tube

All of my frames are line bored with an adjustable carbide cutter to insure a perfect seat post fit.

Another Nameless Repair!

This is also a new downtube repair for a titanium production frame . Just for education purposes , I am sharing this photo to show that this frame was not fusion welded, as by evidence that you can see the tube is separate from the actual weld, ( you can see the line between the two). It is important to do a fusion weld ( fusing the two parts together without using welding filler rod). This process done correctly insures that there is a deep weld bond between the two parts, in this case the bottom bracket and the downtube. If you click on the photo you can see this clearly. I hope these photos will help the interested bicycle enthusiast learn more about the building process!

Repairs, Repairs and More Repairs!

Over the years I have taken on quite a few titanium repairs of other brands of bikes other than my own. It is hard to turn down someone trying to get some more life out of their trusty old bike. It has also given me a lot of insight on why some of these frames are failing. I am always asked why someone should buy one frame over another , or more to the point, why should someone buy one of my frames over another brand. So being a custom builder I am always in a position to try to educate my potential customer how I build a frame differently than others. The frame shown above which will remain nameless, was a repair for a broken downtube. Upon cutting out the downtube I discovered that the seatube purge hole is in the wrong place and the seat tube was not welded to the bottom bracket at all underneath the downtube. This is definitely one of the differences on my frames , my seat tubes are completely welded to the bottom bracket before further assembly. This makes a stronger more reliable frame!

New Touring Bike!

This is a bike that I hope I get a chance to ride! Yep, I think this bike will fit me too! See you soon John!

Silk Ti Breakaway Race Proto

This is a Silk Ti Breakaway I made for Tom Ritchey to race in Europe. He wanted a bike he could carry on and not loose. It features Tom's integrated head tube, and his Breakaway technology, with the Castellano Silk Ti technology. Fun bike to build and a fun bike to ride! Brennan has his eye on this one, he is quite the bike collector!

Have You Seen This Before!

This is what you get when someone wants a Single Speed Silk Ti with Paragon Sliders. Thanks to John Castellano's design and engineering skills when it comes to solving new challenges with this custom request!

Touring Sideview

Steve Potts custom made frame and fork with rack and fender mounts front and rear.

Full On Touring !

This bike is going to be a hard one to let go! It is set up for front and rear racks and fenders ! The totally functional bullet proof bike !