D4E1 HomeTrainer

http://designforeveryone.howest.be/

PEDALOKRUKKEN 3.4

http://designforeveryone.howest.be

Jan Leyssens / Jan Van Loo / Thomas Vandendriessche

260 minutes€ 170

http://pedalokrukken2010.blogspot.com

ASSEMBLY MANUAL


BILL OF MATERIAL- 18mm multiplex plate – 6 tailor made parts- 9mm multiplex plate – 4 tailor made parts- 2 pedals- 2 pedal supports- 500 mm ribbon hinge- Handlebars tape- 2 x 25mm screw- 10 x 35mm screw- 32 x 15mm screw- 200ml glue (for wood)- 3 wheels with a 60mm on 18mm base and 45mm diameter- 2 x 14mm inner diameter ring- 2 x 12mm inner diameter ring- 2 x 10mm diameter and 30 mm long spring- 2 x M12 bolt and nut- 2 x M6 bolt and nut- Cupboard handle (shape is not important)- 30mm M4 spindle- Piece of Teflon 18x18x30mm- 2 trestle hinges- TEC7 (silicon superglue)- Paint (optionally)- Saddle

PEDALOKRUKKEN 3.4

8 different tools (accessories not included).

14 different standard components.

10 parts have been made tailored.

01

Technical addendum 4

Eyes

Bill Of Materials

No definitive part have been added

This action costs €0

PEDALOKRUKKEN 3.4

60 minutes action

DESCRIPTION It can be useful to start with arranging all the components to get a clear view of the total assembly. Most of the parts are made from wooden multiplex plates. There might be some difference in colour or damaged parts. Carefully check the parts and select which sides are the best to show.In order to avoid unwanted situations check the bill of materials mentioned before and inspect all the needed materials.

NOTE: it is easier to assemble this home trainer with two people.

02

Technical addendum 1 & 2

Wood glue

0 standard components are used

2 part have been added


PEDALOKRUKKEN 3.4

5 minutes action

DESCRIPTION It takes a while for the glue to dry, so it is important to start with the glue actions. First of all glue one of the two “body” parts of 9mm and the 18mm “body” together.

03 PEDALOKRUKKEN 3.4

DESCRIPTION Fix the construction with cramps. Some wood remains are helpful to protect the parts and distribute the pressure more equally.

No technical plan needed

Some cramps




5 minutes action

04


Silicon pistol (+ grinding machine)

2 pedal supports

1 part has been added


PEDALOKRUKKEN 3.4

15 minutes action

DESCRIPTION While the glue of the first subassembly is drying there is some time to start preparing the pedal construction. Use the TEC7 silicon superglue to fix the two pedal supports in the foreseen milled holes. If the pedal supports are to long, a grinding machine can be used to shorten them.

OPTIONALLY: paint the part in a preferred colour. This colour will later on accent the pedals.

05


Electric drill

2 rings + 8 screws



PEDALOKRUKKEN 3.4

15 minutes action

DESCRIPTION Make a draft assembly to see how the circles would look like on the final model (with pedals and the necessary rings). Bore 4 holes in the ring and fix it with 4 screws. Repeat this action at the other side. These rings will fix the pedal supports.

OPTIONALLY: to make the construction even stronger the screws can be replaced by bolts.

06 DESCRIPTION One of the two circles of 9mm and the 18mm circle have to be glued together.Pay attention to the construction at the bottom. This will be used to centre the two circles together. The metal pieces are 10mm thick because there is a difference of 10mm between the radii.

Technical addendum 1 & 2

Piece of wood

Wood glue



PEDALOKRUKKEN 3.4

5 minutes action

07 DESCRIPTION The previous described construction makes it easy to position the two circles. The inner circle has to be concentric with the screw thread, therefore a sliding calliper can be used. Fix the composition with two 25mm screws.

No technical plan of this part.

PEDALOKRUKKEN 3.4

Electic drill

2 x 25mm screws



5 minutes action

08 DESCRIPTION Disassemble the draft assembly and squeeze the circles together with cramps.

PEDALOKRUKKEN 3.4


Cramps




2 minutes action

09 DESCRIPTION While the two sub-assemblies are hardening, there is time to get on with the other parts.Take the handlebars and the handlebars-support and indicate where it has to hinge.

PEDALOKRUKKEN 3.4


Pencil



2 minutes action


10 DESCRIPTION Position the hinge on the previously made indication. Attach it with some screws. Pay attention to the angle of the hinge. Try to connect the hinge in a way that you avoid screwing parallel with the multiplex plate.

PEDALOKRUKKEN 3.4


Electic drill



10 minutes action

500mm ribbon hinge + 16 x 15mm screw

11 DESCRIPTION Screw down the trestle hinges. In this case it is not possible to avoid screwing parallel with the multiplex plate. It is necessary to drill small holes before adding the screws.

5 minutes action

Electric drill (bit and twist bit)

2 trestle hinges + 4 x 15mm screw

2 parts have been added

PEDALOKRUKKEN 3.4



12 DESCRIPTION Wind the handlebars tape around the handlebars. There are notches provided. It is important to wind it very strong and with a small pitch.If the handlebars tape doesn’t stick enough, use PVC tape.

PEDALOKRUKKEN 3.4

15 minutes action

Some extra pvc tape can be useful

Handlebars tape (and PVC tape)




13 DESCRIPTION Use the superglue to fill the thread of the handle. Thereupon screw the spindle in the handle.

OPTIONALLY: paint this part in the preferred colour. In this project all functional parts are coloured black.

No tools are used in this action

PEDALOKRUKKEN 3.4


M4 spindle + Cupboard handle + Superglue

3 minutes action



14 DESCRIPTION Drill holes in the remaining wood for the spindle. Use a 3,5mm drill. The M4 spindle can be screwed in the wood. This is necessary to create a pressure on the piece of Teflon afterwards.

PEDALOKRUKKEN 3.4

Electric drill + 3,5mm drill


3 minutes action




15 DESCRIPTION Screw the two lowest wheels on the 18mm body. Hold the remaining wheel against the upper notch. Indicate the corresponding spots from the wheel housing on the wood. Drill two 8mm holes on these marks.

PEDALOKRUKKEN 3.4

Electric drill


5 minutes action



4 x 15mm screw

16 DESCRIPTION Again make a draft – not definitive – assembly to check all dimensions and functions.At this stage the assembly should look like this picture.

PEDALOKRUKKEN 3.4

10 minutes action



No tools are used in this action



17 DESCRIPTION Spread the glue on the 2 connected bodies. Be sure to use enough glue. This step is very important and irreversible.

PEDALOKRUKKEN 3.4

10 minutes action



Piece of wood to spread the glue


Wood glue

18 DESCRIPTION Position the remaining 9mm body carefully on the glue. Wood glue allows small moves the first minutes after connection. Next, squeeze the assembly together with cramps.

PEDALOKRUKKEN 3.4

10 minutes action



Piece of wood to spread the glue


Wood glue

19 DESCRIPTION With all bodies assembled, the main part is ready. Add the piece of Teflon. Probably the dimensions of the standard piece will not fit in the foreseen hole. A metal saw is the ideal tool to form the Teflon.

PEDALOKRUKKEN 3.4

3 minutes action



Piece of Teflon


Metal saw

20 DESCRIPTION Make a subassembly for the last wheel. Screw two bolts through the holes in the wheel housing. Fix them with nuts using spanners. Add the two springs as shown on the picture. Assemble the subassembly to the body.

PEDALOKRUKKEN 3.4

6 minutes action



Some spanners


1 wheel + 2 springs + 2 bolts + 2 nuts

21 DESCRIPTION Assemble the body with the wheels and the two connected circles. Place the last 9mm circle on the assembly and make sure the margin is equally divided using folded snippings of papers.

PEDALOKRUKKEN 3.4

5 minutes action



Snippings of papers



22 DESCRIPTION Attach the circle with 6 screws. Don’t use glue for this step. The screws allow to easily optimise the inner wheels or Teflon when something seems to be wrong.

PEDALOKRUKKEN 3.4

5 minutes action


Electric drill

6 x 35mm screws



23 DESCRIPTION This action demands some improvisation. Depending on the preferred kind of saddle their might be another manner of attaching the saddle to the saddle pin. Generally the original saddle pin has to be removed and some extra wood pieces and screws can make a strong and secure connection.


PEDALOKRUKKEN 3.4

30 minutes action


Electric drill + spanners

Saddle + 2 x M12 bolts and nuts + Screws


24 DESCRIPTION Assemble the two braces. Normally, no tools are required for this job. If the fitting seems to tight, the “body”-plates might have shifted while hardening. Use abrasive paper to smoothen the gaps or use a hammer to force it. Please note that using a hammer can make this action irreversible.

PEDALOKRUKKEN 3.4


10 minutes action


Abrasive paper/hammer optional



25 DESCRIPTION Attach the pedals. Make sure to attach the left pedal on the left side of the home trainer.Fix the pedals as tight as possible, this will reduce chance of the pedals to wiggle loose.

PEDALOKRUKKEN 3.4

6 minutes action


Spanner


2 pedals


26 DESCRIPTION Insert the previously made assembly with the handlebars.As described in step 24, this step should be pretty straightforward. If the handlebars do not fit immediately, use abrasive paper or a hammer.

PEDALOKRUKKEN 3.4


5 minutes action


Abrasive paper/hammer optional

1 sub-assembly has been added


ADVANTAGES • Tailor made design

• Wheel height• Distance between pitch circle and saddle

• Adjustable saddle• Wide footboard• Very small design• Entirely flat surfaces, no obstacles for the feet• Wooden base structure for add-on connections• Variable resistance• Low priced, easy to create home trainer

PEDALOKRUKKEN 3.4

ACCESSORIES


1 DESCRIPTION If standard pedals are not big enough for your comfort, you can easily make add-ons to tackle this problem.By screwing 2 pieces of wood together, you can make an extra support as shown in the picture.To attach the add-on to the pedal(s), use straps or glue.

PEDAL EXTENSIONS 1.3

2 DESCRIPTION For those that experience difficulties getting on or off the home trainer, a footboard was designed.This footboard will give you a higher degree of freedom when getting on or off, and it collapses once seated.One way of creating this is by using a door-spring that helps during the collapsing and restoring of the footboard.This movement can be connected to the hinging of the handlebars.

FOOTBOARD 1.0

3 DESCRIPTION When adding extras to the home-trainer, the possibility arises that the pedals are to close to the floor or hit other objects.To avoid this, a bike holder is created.Other useful advantages of this holder are more stability, floor protection and a finishing touch.

BIKE HOLDER 1.0

TECHNICAL ADDENDUM


ADDENDUM 1 Wooden plate 9mm – parts composition

ADDENDUM 1.1 Wooden plate 9mm – Body (2x)

ADDENDUM 1.2 Wooden plate 9mm – Circle (2x)

ADDENDUM 2 Wooden plate 18mm – parts composition

ADDENDUM 2.1 Wooden plate 18mm – Body

ADDENDUM 2.1 Wooden plate 18mm – Handlebars

ADDENDUM 2.1 Wooden plate 18mm – Brace (2x)

ADDENDUM 2.1 Wooden plate 18mm – Handlebars support

ADDENDUM 2.1 Wooden plate 18mm – Circle

ADDENDUM 2.1 Wooden plate 18mm – Saddle pin

ADDENDUM 3 Dimensions related to the users physique

DESCRIPTION By connecting the dimensions of the home trainer with an Excel sheet, the entire model can be turned into a fully personalised home trainer in just a few seconds.

ADDENDUM 4 Exploded view

ADDENDUM 5 Computer render

ADDENDUM 5 Final result

TEAM CONTACTS

http://designforeveryone.howest.be/

[email protected] +32 479 06 88 04




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