Because I like to keep things simple, the bicycle I am making is of course a low trail design. And low trail means a fork with a lot of rake. A very curvy fork, in other words. Not only did I want it to be curvy, but I wanted it to be that special kind of French-curvy where instead of a gradual "banana" bend, there is a dramatic flick toward the tips of the blades (like so).
When you buy supplies for making a fork, what you get is two straight blades that are (hopefully) a bit longer than you need them to be, and a crown which those blades plug into. It is then up to you to rake the blades. The style of bend I wanted requires using blades that are designed to withstand such dramatic manipulation. I went with the Kaisei Toei blades, which were already familiar from other projects I've been involved in.
To get the fork blades bent as desired, we needed a special setup that was not locally available. So we payed a visit to Cirlce A Cycles in Providence RI, about 30 miles from Mike Flanigan's shop. They have a fork bender that was made specifically for the French-style bend and could produce the 73mm of rake I wanted. The furry receptionist granted us permission to use it.
Since 73mm is a pretty dramatic amount of rake, Chris Bull suggested filling the fork blades with sand before bending. This would reduce the possibility of damage during the process.
The blades were taped at both ends to contain the sand.
The fork bending press consists of a wooden block curved according to the French bend design (they have several of these presses, used for different styles of bends). There is a notch along the curve where the fork blade sits, held in place by a vise.
A giant lever is then pushed up, forcing the blade to adhere to the curvature of the wooden block.
The further up you push, the more dramatic the bend.
At first we did not have an idea of exactly when to stop, so Chris eyeballed it and stopped when he thought the rake was around 50mm. Confirming that this was correct and that the bend was forming properly, he then continued the process until we finally had the 73mm rake we wanted.
This is the dropout placement mockup. To determine the rake correctly, you need to know how and where the blade will be connected to the dropout.
One thing that can go wrong during this process, is that the steel can get distorted. When this happens, you can see and feel a rippling on the inside of the bend. Thankfully this did not happen.
For the second blade we now knew exactly when to stop and had a marker in place. I did part of this bend myself and it was pretty cool to feel the blade give under the force of the lever. It is interesting that Circle A's setup makes you push the lever up rather than pull it down; I have never operated this kind of press before.
Thanks to Circle A, I now have two symmetrical, beautifully raked fork blades that are waiting to become a fork. All I have to do is braze it.

Scrambling the second summit (photo by Steve Machuga)
Near Keflavik, Iceland. Summer of 1973.Copyright © 1973/.. by Rebeckah R. Wiseman


My backside run (photo by Steve Machuga)
Steve on the backside
Hotshot


This bench was outside one shop door and looked like it was worth taking a picture of.
Irwin Joslin and his wife Alice.
Second cousins. Irwin Laverne Joslin and Hazlette Ferguson.

Half Dome and Vernal Falls as seen from Washburn Point (on the way to Glacier Point). The gray and gloomy skies give it a rather forbidding appearance.
Yosemite Valley and Half Dome from Glacier Point.
A close-up view of Half Dome, also from Glacier Point.
Upper and Lower Yosemite Falls, from Glacier Point. The sun came out for a few minutes, highlighting the granite walls and mountain tops.
Bridalveil Falls as seen from the bottom of the falls. Yeah, ya can't see much! And I got drenched. And it was fun! The force of the wind-blown water was incredible.
Yosemite Valley with El Capitan on the left and Bridalveil Falls on the right.
Bridalveil Falls.
Yosemite Falls from the meadow in the Valley. Cars and people line the road.
Yosemite Valley from the tunnel overlook at the entrance into the valley. El Capitan is on the left, Half Dome is off in the distance in the center, and Bridalveil Falls on the right.