To make this project a reality we relied heavily on digital design and prototyping. We used Solidworks to model different bike frame as well as the jig and we used CNC routing to make parts that perfectly matched our drawings. This really helped streamline the process and get us to or goal of a bike frame fast.
We are not professional bicycle fabricators. We may or may not have used best practices when fabricating the frame in this instructable. It is the responsibility of the user to ensure that best practices are used. Remember, you're building a bicycle that you or someone else may be riding. You need to be sure that your design and fabrication skills are adequate to produce a bicycle free from mechanical defects. Failure to do so may result in mechanical failure, accident or even death. When constructing a frame you must absolutely keep the safety of you and others in mind. There is a significant risk of fire when using torches and welders for fabrication. You must take the proper safety precautions when using torches and welders. This includes but is not limited to fire extinguishers, ventilation, respirators, protective eye wear, protective clothing and to keep flammable materials away from the area you are working in. You'll be using different fluxes and solvents during this project that can be poisonous. Be sure to wear the proper clothing, gloves, etc... to protect your skin and eyes from these chemicals. Remember, use common sense and when in doubt stop what you are doing and research the proper methods.
There are many resources available that teach proper frame design and fabrication. An especially helpful manual is the Paterek Manual for Bicycle Frame Builders. Copies can be found for sale online.