Tuesday, January 03, 2006
Build Day 4
The Foam was cut tonight, as well as the two dropouts from a donor frame. The dropout shape will be used as a template for custom mounts into the rear fork.
This was a rough cut, more shaping will need to be done later. I am really liking this dremel tool - using it to mill this shape was quick, easy and provided a very smooth surface.
Tomorrow I will acquire glue, cut the rear fork/foam and cut the bottom bracket out of donor bike. I might also need to buy new bearings for the head tube cups (I seem to have misplaced them while moving across my back yard). Should only add a few dollars at the LBS.
Monday, January 02, 2006
Build Day 3 - tiny bit done
After a long hiatus in which no work has been done, I started up again tonight. The steering races have been cut from a donor frame.
I am also thinking about using the dropouts from this frame in my 'bent. They look long enough, I will have to see about tapping them.
So officially, this is the third build day...
Shopping list:
Foam
6 hour laminating epoxy
plate steel or aluminum
A few blocks of wood
Sand Paper
Brake/Shifter Cable
Stuff for seat
...
Wednesday, December 21, 2005
Day 4
No new mfr progress today. I spent my time with Carrie :)
I am looking at method to bend plywood in order to form a seat. It looks like I will be soaking a rough cut of the seat in water - then giving it a hot shower and I will use clamps and straps to form the seat against the frame. I'll need to have the frame and rear fork completed before I get to this stage.
I am looking at method to bend plywood in order to form a seat. It looks like I will be soaking a rough cut of the seat in water - then giving it a hot shower and I will use clamps and straps to form the seat against the frame. I'll need to have the frame and rear fork completed before I get to this stage.
Tuesday, December 20, 2005
Day 3 - Frame Cutout
Today I finalized my design. After being pleased with the shape, I cut out the main frame body with my jigsaw. I am quite pleased with the result. Some fine tuning with sandpaper will be required. Currently I only have 24" wheels. hopefully I will be able to source a smaller front wheel and maybe a larger rear.
Tomorrow I plan on having the rear fork parts cut out - then I can move on the shaping the foam and laminating.
Tomorrow I plan on having the rear fork parts cut out - then I can move on the shaping the foam and laminating.Monday, December 19, 2005
Day 2
Nothing New To Report.
I spent the day working on my parent's car - replacing timing chain. Not finished yet because of rain. The evening was spent shopping. A few design changes have been made to the sketches for a more fluid and slim shape.
I spent the day working on my parent's car - replacing timing chain. Not finished yet because of rain. The evening was spent shopping. A few design changes have been made to the sketches for a more fluid and slim shape.
Sunday, December 18, 2005
Day 1 - Getting Started
The plan:
A wood / foam composite recumbent bike frame using 1/4" sandewood plywood (strong, light and good looking), and 2" Styrene insulating foam. All sourced from the local home improvement store. Parts will be sourced from donor bikes.
The Goal:
Something that works of course. Minimal Welding/brazing (if any). Dropouts will be custom aluminum and the headset will be supported by custom aluminum brackets. Controls should be comfortable and the ride should also be comfortable too. The bike must have storage for my backback for commuting to class. I should also be able to drive it up to school (200 miles) and be able to lock it up safely outside.
The Design:
Because I am not yet skilled enough to do a Finite Element Analysis (don't fret on what that means), I will be basing my design off of similar recumbents that may be found on this website:
http://www.blids.nl/gallery/PlywoodRecumbentBuildingworkshop2003 . I wish to ensure a success so going off a shape that already works is a great start.
My sketch:
Not to Scale:
The design will be fluid and form to my body as best I can.
Now to the actual day:
-----
I got parts today from the local home improvement store. With three donor bikes already secured, I'm ready to start building a frame. As my break is short, I must work quickly and carefully. I bought two sheets of sandewood ply for about $17ea.USD + tax. My girlfriend Carrie helped me load and unload the wood into the back cabana house: AKA bike build ground zero.
I put one piece of wood flat on the ground and I took two of my 24" wheels and set them on the wood for positioning. I drew a rough sketch of the bike using pencil. By sitting in a vertical position mimicking the rider position, I was able to get rough measurements of the length and height (by falling over :P).
Click the Image For Bigger View. The Sketch is just barely visible.
One Headset disassembled.
A wood / foam composite recumbent bike frame using 1/4" sandewood plywood (strong, light and good looking), and 2" Styrene insulating foam. All sourced from the local home improvement store. Parts will be sourced from donor bikes.
The Goal:
Something that works of course. Minimal Welding/brazing (if any). Dropouts will be custom aluminum and the headset will be supported by custom aluminum brackets. Controls should be comfortable and the ride should also be comfortable too. The bike must have storage for my backback for commuting to class. I should also be able to drive it up to school (200 miles) and be able to lock it up safely outside.
The Design:
Because I am not yet skilled enough to do a Finite Element Analysis (don't fret on what that means), I will be basing my design off of similar recumbents that may be found on this website:
http://www.blids.nl/gallery/PlywoodRecumbentBuildingworkshop2003 . I wish to ensure a success so going off a shape that already works is a great start.
My sketch:
Not to Scale:The design will be fluid and form to my body as best I can.
Now to the actual day:
-----
I got parts today from the local home improvement store. With three donor bikes already secured, I'm ready to start building a frame. As my break is short, I must work quickly and carefully. I bought two sheets of sandewood ply for about $17ea.USD + tax. My girlfriend Carrie helped me load and unload the wood into the back cabana house: AKA bike build ground zero.
I put one piece of wood flat on the ground and I took two of my 24" wheels and set them on the wood for positioning. I drew a rough sketch of the bike using pencil. By sitting in a vertical position mimicking the rider position, I was able to get rough measurements of the length and height (by falling over :P).
Click the Image For Bigger View. The Sketch is just barely visible.One Headset disassembled.
