wood bike 2

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22/1/2015 Wood Bike 2

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Wood Bike 2

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http://cdn.instructables.com/F5O/JIWW/GN4CZWJF/F5OJIWWGN4CZWJF.LARGE.jpg


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I got into wood bikes recently. I made Wood bike 1 and then have been looking on the

net and elswhere for ideas for number 2. I found one on this site that I loved

http://www.instructables.com/id/Bent-Plywood-Bicycle/[7]. This bike and others

inspired me to make my own bent bike. I am fairly competent with tools and have a lot

of bits and pieces in my shed.

It took me 3 full days and cost about $100 and a donor bike. I have a bit of tidying up

to do but its pretty much finished.

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Step 1: Getting started.
http://cdn.instructables.com/FDI/T973/GN02QRWL/FDIT973GN02QRWL.LARGE.jpghttp://www.instructables.com/id/Wood-Bike-2/?ALLSTEPS#more-anchorhttp://cdn.instructables.com/FNZ/ME5Y/GN4CZWJE/FNZME5YGN4CZWJE.LARGE.jpghttp://www.instructables.com/id/Bent-Plywood-Bicycle/http://cdn.instructables.com/FMH/0YSY/GN4CZF1B/FMH0YSYGN4CZF1B.LARGE.jpghttp://cdn.instructables.com/FDI/T973/GN02QRWL/FDIT973GN02QRWL.LARGE.jpghttp://www.instructables.com/account/gopro?sourcea=removeads&nxtPgName=Wood+Bike+2&nxtPg=/id/Wood-Bike-2/?ALLSTEPShttp://cdn.instructables.com/FUU/TBNQ/GN4CZF15/FUUTBNQGN4CZF15.LARGE.jpg


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First I got a bit of ChipBoard big enough to fit the bike on and make my bending jig.

Then I put my bike on it and traced the frame with a pencil. Once I had an outline Iused a bendy bit of yellow plastic to work out the curves that I like. I used a couple of

screws to hold it into place while tracing

I had a $20 donor bike and decided to copy the frame geometry. I think its a fairly good

bike but its about to cease to exist.

Step 2: Supplies and my Jig
http://cdn.instructables.com/F6L/WP07/GMVSCYMK/F6LWP07GMVSCYMK.LARGE.jpghttp://cdn.instructables.com/FJ2/86XE/GMVSC5KO/FJ286XEGMVSC5KO.LARGE.jpghttp://cdn.instructables.com/FDH/KTIM/GMIGHX14/FDHKTIMGMIGHX14.LARGE.jpg


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I went to the hardware shop and found a 4 x 8 sheet of 4mm Hardwood bracing ply.

Also 2m of 20mm x 45mm pine to make my bending jig.

The pine I then cut into +\- 150 mm pieces as the uprights on my jig. I then screwed

them to my jig with 2 big screws each and some glue. They have to be fairly strong

because thats what the first layer will be clamped to.

The pic below is just a pic of the jig with a mock up bend just to see if I had enough

clamps. Wel as it turns out I dont have enough clamps- YOU CAN NEVER HAVE

ENOUGH CLAMPS.

Step 3: Cut and laminate
http://cdn.instructables.com/FN7/1201/GMVSD06F/FN71201GMVSD06F.LARGE.jpg


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Today I drew the shapes i want on one piece of ply and screwed 5 together. Then I cut

out the shape with a circular saw and a router for the tricky bits.

I laminated the both sides separately . As I'm using steel for the connections I can

laminate in 2 halves and dont have to do them in one go.

I used 5 layers of 4mm ply and that got me to 24mm total thickness. I used PVA white

glue as it's cheap and I had some. The glue was painted on thick till the complete

surface was covered and then I just clamped them on one by one. After about an hour

each time I just stuck some screws in from the back to hold the last piece in place,
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took the clamps off and glued another one on.

The right way would probably be to wait a day between layers. Its amazing but after

the 3rd one I released all the clamps just to see what would happen and it kept its

shape. This is the first time I bent wood and although I know it works it still blew me

away.

Its all drying in the shed overnight.

Step 4: Release the clamps and sanding

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The curves were released from the mould today. There was a lot of sanding and

planing and routering but I finally got them smooth.

I used and electric plane and a belt sander.

I also started working on the steel bracket that will connect the top and bottom curves

to the steering head.
http://cdn.instructables.com/F7W/JOF5/GMX1Q2VI/F7WJOF5GMX1Q2VI.LARGE.jpg


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Step 5: Chop it up.

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This is the part where I chop up the old bike to get the bits I need. I would wear gloves,

glasses and ear protection as a minimum when working with a grinder.

Firstly I cut the dropouts off. Thats the bits where the back wheels connect to the

frame. Save them for later.

Now I started cutting out the bottom bracket with the seat tube still attached. I use a

125mm angle grinder with a 1mm cutoff disk. It slices like a hot knife through butter.Then I cut the steering neck out as well, while removing brakes and cables and things

as I run into them.
http://cdn.instructables.com/F1C/E6PT/GMYN9UCK/F1CE6PTGMYN9UCK.LARGE.jpghttp://cdn.instructables.com/F73/93YV/GMX1Q2WF/F7393YVGMX1Q2WF.LARGE.jpghttp://cdn.instructables.com/F6Q/O6UZ/GMX1V9D7/F6QO6UZGMX1V9D7.LARGE.jpg


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In the last photo is the result of what I had left over. It took about 1 hour to grind all

the welds off and smooth it all over. I then hit all the grinds with a bit of grey primer

as i live at the beach and it will rust almost over night.

Step 6: Fabrication

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Today was a big one, about 7 hours on the bike. I had some bits of 2mm plate so I cut

some pieces out to make an attachment bracket for the steering head. After lots of

cutting, grinding and halfround filing I was ready for welding.
http://cdn.instructables.com/FCC/6RC6/GMYNB097/FCC6RC6GMYNB097.LARGE.jpghttp://cdn.instructables.com/FZ3/1OZI/GMYN9YI7/FZ31OZIGMYN9YI7.LARGE.jpghttp://cdn.instructables.com/FM2/GT7A/GMX1Q9KE/FM2GT7AGMX1Q9KE.LARGE.jpghttp://cdn.instructables.com/FEH/7E86/GMX1Q9KH/FEH7E86GMX1Q9KH.LARGE.jpg


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All my angles were worked out very loosely by holding all the pieces on the ground

and tracing it on the floor with a pencil, then transfer to paper. I then cut out the

paper and transfered to steel plate for cutout.

So I cut the 3 pieces out and welded them all together to the steering head tube.

Step 7: Dropout brackets

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For the dropout brackets I had to do some Blacksmithing. First I drew it up roughly on

the ground again and transferred to paper.

Now remember when I cut off the dropouts before and told you to save them for later.

Well this is later. I cut out the shape out of plate and bent, blowtorched and

hammered till I had these brackets. I then welded it all together and also welded the

dropouts on.

I probably should have approached this more scientifically but...

A bit of primer paint after welding is always a good idea.

Step 8: Assembly

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This is where I started screwing things together. I used 20mm wood screws for testing

but I now replaced them with 6mm bolts with nylocker nuts. I had to do a fair bit oftrimming on the frame to make it all fit. The wheel hit the sides and I had to adjust the

brackets a bit. I didn't spend too much time measuring things I just kindof made it up

and adjusted where needed.

Other than that it all went together nicely.

Step 9: Seatpost and bottom bracket

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For the seatpost I drilled a 28mm hole in the top beam. On the bottom of the bottom

bracket I welded a mounting plate that you can see in the second photo. I forgot to

take a photo as I made it. I then stuck the seatpost tube through the hole from

underneath and screwed the mounting plate to the bottom beam.

I am making a little wooden box to cover the ugly bottom bracket. I still need to do

another couple of coats of varnish and back brakes and front derauler. Other than that

the bike is done and very strong.

I then put all the bike bits on and it was test drive time. I had to stop a couple of times

for adjustments but it felt very strong. At first I let the seatpost slide through the top

beam so all my weight pressed on the bottom beam only. It was nice and springy but

not in a good way. There was no shock absorbtion and it didn't improve the ride at all

just very bouncy. I didnt like it so I put a couple of screws in to stop the seatpost from

sliding. The bike now feels solid to ride and I gave it heaps of testing: Up and down

pavements, wheelies, stoppies, top speed down the road , 150kg load test. Its all

holding up.

Step 10: Photos
http://cdn.instructables.com/FSF/BD06/GN02QRWZ/FSFBD06GN02QRWZ.LARGE.jpghttp://cdn.instructables.com/FSF/BD06/GN02QRWZ/FSFBD06GN02QRWZ.LARGE.jpg


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1. http://cdn.instructables.com/F5O/JIWW/GN4CZWJF/F5OJIWWGN4CZWJF.LARGE.jpg

2. http://cdn.instructables.com/F0K/TOU2/GN02OZAS/F0KTOU2GN02OZAS.LARGE.jpg

3. http://cdn.instructables.com/FDI/T973/GN02QRWL/FDIT973GN02QRWL.LARGE.jpg

4. http://cdn.instructables.com/FMH/0YSY/GN4CZF1B/FMH0YSYGN4CZF1B.LARGE.jpg

5. http://cdn.instructables.com/FNZ/ME5Y/GN4CZWJE/FNZME5YGN4CZWJE.LARGE.jpg

6. http://cdn.instructables.com/FUU/TBNQ/GN4CZF15/FUUTBNQGN4CZF15.LARGE.jpg

7. http://www.instructables.com/id/Bent-Plywood-Bicycle/

8. http://www.instructables.com/account/gopro?

sourcea=removeads&nxtPgName=Wood+Bike+2&nxtPg=/id/Wood-Bike-2/?

ALLSTEPS

9. http://cdn.instructables.com/FJ2/86XE/GMVSC5KO/FJ286XEGMVSC5KO.LARGE.jpg

10. http://cdn.instructables.com/FDH/KTIM/GMIGHX14/FDHKTIMGMIGHX14.LARGE.jpg

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Some photos and one of woodbike1 as well.

Links
http://cdn.instructables.com/FSF/BD06/GN02QRWZ/FSFBD06GN02QRWZ.LARGE.jpghttp://www.instructables.com/id/Bent-Plywood-Bicycle/http://cdn.instructables.com/F5O/JIWW/GN4CZWJF/F5OJIWWGN4CZWJF.LARGE.jpghttp://cdn.instructables.com/FDI/T973/GN02QRWL/FDIT973GN02QRWL.LARGE.jpghttp://cdn.instructables.com/F0K/TOU2/GN02OZAS/F0KTOU2GN02OZAS.LARGE.jpghttp://cdn.instructables.com/FNB/QL8V/GMX1QGF3/FNBQL8VGMX1QGF3.LARGE.jpghttp://www.instructables.com/id/Wood-Bike-2/?ALLSTEPS#more-anchorhttp://cdn.instructables.com/FNB/QL8V/GMX1QGF3/FNBQL8VGMX1QGF3.LARGE.jpghttp://cdn.instructables.com/F0K/TOU2/GN02OZAS/F0KTOU2GN02OZAS.LARGE.jpghttp://cdn.instructables.com/FDI/T973/GN02QRWL/FDIT973GN02QRWL.LARGE.jpghttp://cdn.instructables.com/FUU/TBNQ/GN4CZF15/FUUTBNQGN4CZF15.LARGE.jpghttp://cdn.instructables.com/FNZ/ME5Y/GN4CZWJE/FNZME5YGN4CZWJE.LARGE.jpghttp://www.instructables.com/account/gopro?sourcea=removeads&nxtPgName=Wood+Bike+2&nxtPg=/id/Wood-Bike-2/?ALLSTEPShttp://cdn.instructables.com/FJ2/86XE/GMVSC5KO/FJ286XEGMVSC5KO.LARGE.jpghttp://cdn.instructables.com/FIP/LGKJ/GN02OZAP/FIPLGKJGN02OZAP.LARGE.jpghttp://cdn.instructables.com/FSF/BD06/GN02QRWZ/FSFBD06GN02QRWZ.LARGE.jpghttp://cdn.instructables.com/FDH/KTIM/GMIGHX14/FDHKTIMGMIGHX14.LARGE.jpghttp://cdn.instructables.com/FMH/0YSY/GN4CZF1B/FMH0YSYGN4CZF1B.LARGE.jpg


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11. http://cdn.instructables.com/F6L/WP07/GMVSCYMK/F6LWP07GMVSCYMK.LARGE.jpg

12. http://cdn.instructables.com/FN7/1201/GMVSD06F/FN71201GMVSD06F.LARGE.jpg

13. http://cdn.instructables.com/FB3/461S/GMX1Q2VG/FB3461SGMX1Q2VG.LARGE.jpg

14. http://cdn.instructables.com/F68/W1IV/GMVSD4SS/F68W1IVGMVSD4SS.LARGE.jpg

15. http://cdn.instructables.com/FUI/PP00/GMYN9U9V/FUIPP00GMYN9U9V.LARGE.jpg

16. http://cdn.instructables.com/FWV/VRR1/GMYNAPAQ/FWVVRR1GMYNAPAQ.LARGE.jpg

17. http://cdn.instructables.com/F7W/JOF5/GMX1Q2VI/F7WJOF5GMX1Q2VI.LARGE.jpg

18. http://cdn.instructables.com/F6Q/O6UZ/GMX1V9D7/F6QO6UZGMX1V9D7.LARGE.jpg

19. http://cdn.instructables.com/F1C/E6PT/GMYN9UCK/F1CE6PTGMYN9UCK.LARGE.jpg

20. http://cdn.instructables.com/F73/93YV/GMX1Q2WF/F7393YVGMX1Q2WF.LARGE.jpg

21. http://cdn.instructables.com/FZ3/1OZI/GMYN9YI7/FZ31OZIGMYN9YI7.LARGE.jpg22. http://cdn.instructables.com/FEH/7E86/GMX1Q9KH/FEH7E86GMX1Q9KH.LARGE.jpg

23. http://cdn.instructables.com/FM2/GT7A/GMX1Q9KE/FM2GT7AGMX1Q9KE.LARGE.jpg

24. http://cdn.instructables.com/FCC/6RC6/GMYNB097/FCC6RC6GMYNB097.LARGE.jpg

25. http://cdn.instructables.com/FAV/VZG9/GMYN9YJ3/FAVVZG9GMYN9YJ3.LARGE.jpg

26. http://cdn.instructables.com/F45/CJJQ/GMYNB0BS/F45CJJQGMYNB0BS.LARGE.jpg

27. http://cdn.instructables.com/FX3/NN6S/GMYN9YK5/FX3NN6SGMYN9YK5.LARGE.jpg

28. http://cdn.instructables.com/F62/VZNK/GMX1Q9L2/F62VZNKGMX1Q9L2.LARGE.jpg

29. http://cdn.instructables.com/F3V/7GI0/GMYN9YKJ/F3V7GI0GMYN9YKJ.LARGE.jpg

30. http://cdn.instructables.com/FB4/2A59/GMYNB0DF/FB42A59GMYNB0DF.LARGE.jpg

31. http://cdn.instructables.com/FBJ/PJO3/GMX1Q9LX/FBJPJO3GMX1Q9LX.LARGE.jpg

32. http://cdn.instructables.com/FV4/LB80/GMYNB0DH/FV4LB80GMYNB0DH.LARGE.jpg

33. http://cdn.instructables.com/FHZ/M633/GMYN9UCG/FHZM633GMYN9UCG.LARGE.jpg

34. http://cdn.instructables.com/FNB/QL8V/GMX1QGF3/FNBQL8VGMX1QGF3.LARGE.jpg

35. http://cdn.instructables.com/FSF/BD06/GN02QRWZ/FSFBD06GN02QRWZ.LARGE.jpg

36. http://cdn.instructables.com/F0K/TOU2/GN02OZAS/F0KTOU2GN02OZAS.LARGE.jpg

37. http://cdn.instructables.com/FDI/T973/GN02QRWL/FDIT973GN02QRWL.LARGE.jpg



40. http://cdn.instructables.com/FIP/LGKJ/GN02OZAP/FIPLGKJGN02OZAP.LARGE.jpg
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