The Endeavor frame was TIG welded from 7005 series aluminum. The entire process began with Pro-Engineer computer modeling of all tubes, from which each component was cut and mitered to ensure an accurate fit. After welding, the frame was artifically aged by Stak Metallurgical Services to relax the stresses induced by previous fabrication steps. As a final touch, 25+ hours of hand polishing with Rolite Metal Polish were performed to impart a high-luster shine. Simultaniously, a fiberglass ferring was modeled and tested using a viriety of CAD software. A male mold was then made from CNC ribs derrived from the cad file, filled with foam, and coated with bondo. This
mold was then used to create the final ferring which was mounted to the bike for the competition.
 
 
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