Transportrollator2012 montageplan7

http://designforeveryone.howest.be/

http://creativecommons.org/licenses/by-nc-sa/3.0/nl/

TRANSPORTROLLATOR 1.8


Thijs Platteau/ Bram De Craecker

Overall production time: 2 daysOverall cost: €180 (all tools included)

http://transportrollator2012.blogspot.com/


ASSEMBLY MANUAL



BILL OF MATERIALS- Multiplex (700 x 500 x 18mm)-Ayous (150 x 40 x 50 mm)- Volkern (750 x 400 x 8mm) (200 x 300 x 15mm)- Afzelia (70 x 70 x 50 mm)- Beech (300 x 50 x 50 mm)- Formica laminate black (1500 x 600mm)- Aluminium strip (35 x 100 x 2mm)- Aluminium profile (15 x 15 x 2 x 800)- Inox pipe (diam.42 x 3 x 30mm) - Bike pedal - Gardena connection piece (female)- Lock system- Closet door handle ( diam.14 x 22mm)- 8 Rivets (3.2 x 9mm)- 16 Screws (3.5 x 25mm)- 30 Screws (3 x 16 mm)- 1 Screw (6x100mm)- 2 Washers (M16)- 4 Hinges (62 x 25mm)- 1 Hinge (50 x 20mm)- Skai grey (1500 x 1500mm)- White rope (500 x 3mm)- Wood glue- Laminate contact glue- Textile glue- TEC7- Black paint mat- Metal Plastic- Filler - Velcro (0.5m)


19 different tools needed

6 standard parts

14 parts tailored

1 DESCRIPTIONMill the platform with a CNC woodworking machine out of a Volkern board (700 x 450 x 6 mm). HINT: make sure your cutters are freshly sharpened, because the Volkern material is very hard. Also do not mill out in one step, but take something like 3 steps to complete the whole thickness.


See Technical Addendum 1

37min. 15 sec. (only milling)

CNC woodworking machine

Volkern plate 8mm

none

€ 40.35

RESULTIf everything is done correctly, your result should look like this.


2 DESCRIPTION Find an old bike and take off one of the pedals. Start adjusting it with your grinding disc to achieve the right length as can be found on the technical drawing. Weld an inox cylinder at one end and two washers (M16) at the other end (where the pedal used to be). Refine the welds with a round file. The outer washer has two slots, made with a metalsaw.

See Technical Addendum 2.1

1h

Grinding disc, welder, round file

Washers M16, inox pipe (diam. 42mm)

Bike pedal

€ 4


3 DESCRIPTION You can now refine the blends and the holes in the metal with Metal Plastic filler. Smoothen it afterwards with sanding paper.

See Technical Addendum 2.1 .

0.5h

Metal Plastic, sanding paper

none

none

Metal Plastic (500gr.): €6.35


4 DESCRIPTION Check your work one last time with a filler spray and make adjustments if necessary.


0,5h

Filler spray

none

none

Filler spray (400ml): €11.55


5 DESCRIPTION Paint the adjusted bike pedal black, when you’re happy about the results you achieved with the filler. Don’t paint the center piece of the axis, this will be mounted into a support later on to turn the handle. Because the paint wouldn’t stand the friction, we tape this area while painting.

No

5min. (without drying)

Black paint (mat)

none

none

Black spray paint : €6.60


6 DESCRIPTION Adjust a Gardena connection piece (female: connection between hose and tap) with a cutter. Cut of the part where the hose should come and remove the upstanding edge (see picture). This will make sure you can move the grey part from the orange part with maximum distance.

No

5min.

Cutter

Gardena connection piece

none

Gardena connection: €5.30


7 DESCRIPTION Now remove the inner parts of the Gardena connection with a drill or any other tool you can find useful.

No

0.5min.

Drill

Gardena connection piece

none

€ 0


8 DESCRIPTION Glue the adjusted Gardena piece into the cylinder of the adjusted bike pedal with a strong fix-all glue, like TEC7.

No


TEC7 glue

none

none

Fix all glue: € 8.75


9 DESCRIPTION Make a handle on the lathe from a piece of beech wood. And finish it with sanding paper. Other types of wood are also fine, but beech is easy to manipulate.HINT: Use sharp chisels.


20min.

Lathe, chisels

none

none

€ 3


10 DESCRIPTION Make a centered hole in the handle with a drill press. Use a wood drill of 5mm.


2min.

Drill press

none

none

€ 0


11 DESCRIPTION Paint the handle black. Then join the handle to the gardena piece with a long screw (6 x 100mm). The head of the screw gets stuck on the nozzle because of the tensile strain. Now complete the part with the white rope. Make a loop at the end and fix the rope in the two slots of the washer (see next slide).


2min.

Drill

Rope, screw

3

Rope: € 0.5


RESULT If you followed every step, the handle should look something like this.


12 DESCRIPTION Now make the first beam of the conductor on the CNC woodworking machine. Use ayous wood. This is very lightweight and not expensive.


17 sec. (only milling)

CNC woodworking machine

none

First beam

€ 0.31 (milling) + €0.45 (all ayous)


13 DESCRIPTION Finish the first beam by gluing small pieces at the end of the opstanding cubes. Because this is impossible to achieve with the CNC machine we do this now. When a CNC machine is not an easy accessible tool, you can make this whole part with this technique. Just glue all the upstanding part onto a regular beam. This will be less precise of course .


2min.

White wood glue

none

none

White wood glue €3.15


14 DESCRIPTION Make the second beam for the conductor part with a topie milling machine. Make a slot in the ayous piece.


2min.

Topie milling machine

none

Second beam

€0.5


15 DESCRIPTION Make the pieces you need to make a swallow’s tail in Volkern material. Put the circular saw under an angle to achieve the right parts (2outer parts which will be mounted on the conductor and 1 center part which will be mounted on the turning board later on). Sand the outer white layers off to get the black colour out. To do this in a controlled way, it is best to use a sanding machine.HINT: Again make sure the blade of the circular saw is sharp!


45min.

Circular saw, sanding machine

none

Swallow’s tail pieces

€5


16 DESCRIPTION Cover the second beam with formica on one side. Namely the side where you measure 23mm of material. It is also the side where the swallow’s tail will be mounted on.

No

5min.

Contact glue, Spray gun, tape

none

none

€30 (for gluing all formica, also in next steps)


17 DESCRIPTION Make drilling holes into the second beam where later on the swallow’s tail will be mounted. Make a small hole (diam. 4mm) all the way through and a bigger hole (diam. 9mm) till about 15mm from the end (= the side you just covered with formica). This way we can draw the pieces of Volkern for the swallow’s tail from the other side. By doing this no screws will be visible. So drill a hole of 3mm into the pieces of volkern and screw them onto the beam.HINT: Use a Drill press for centered holes

No

20min.

Drill press, drill

none

none

€0.2


18 DESCRIPTION Saw the standard aluminium profile at the right length with a metal saw.

No

5min.

Metal saw

Aluminium profile

none

€0.1


19 DESCRIPTION Now we can finish the second beam completely with formica. Afterwards glue the aluminium profile into the beam with all-round glue.HINT: Saw the formica pieces a bit too large, afterwards you can sand them. For more difficult parts you can use a cutter to complete the form.

No

30min.

Contact glue, spray gun, TEC7

none

none

See step 16


20 DESCRIPTION Spray paint the side with the upstanding parts of the first beam. We do this, because finishing it with formica would be very hard and now the dimensions of the part are just right.

No


Black paint (mat)

none

none

See step 5


21 DESCRIPTION Make the aluminium hooks with a metal saw. Drill holes on the right places and make them tapered with a bigger drill. Make sure to chamfer all edges with a file.


30min.

Metal saw, metal drill, file

Aluminium strip

none

€3


22 DESCRIPTION Screw the finished hooks onto the first beam. Use screws of 3 x 16mm, inox.


2min.

Drill

Screws 3 x 16, inox

none

€0.05


23 DESCRIPTION Finish one side of the first beam with formica(the side that will touch the other beam). Again use a cutter for the more difficult parts of the formica. Also finish the back side (opposite to the side with the hooks).

No

5min.

Contact glue, spray gun

none

none

See step 16


24 DESCRIPTION Screw the two beams together. Make sure you use the right angle and position. Once this is done, you can finish the last side of the first beam. No screws are visible anymore.

No

2min.

Drill

none

none

€ 0.05 + See step 16


25 DESCRIPTION After you finish everything with sanding paper, you can colour the edges black. This wil give you an excellent finish.

No

10min.

Black marker

none

none

€0


26 DESCRIPTION All steps from 12 till 23 have to be done twice, because we need two conductors. But keep in mind they have to be mirror images. So very carefully watch every step, so you can screw them together in the right way (step 24). HINT: When you apply formica onto the ayous wood, always garantee adhesion with pressure (see picture).


/

/

/

/

See step 16


RESULT At the end, the conductors should look like the picture below.


27 DESCRIPTION Now we start making the support. Begin with covering one side of a multiplex board with formica (see technique in previous steps). Drill a hole with diameter 4mm on the right place. Make a second hole for the head of the screw ont the other side of the formica (not all the way through). Then insert the closet door handle and screw it tight (door handle on the side of the formica).


10min.

Contact glue, spray gun, drill press

Closet door handle

Multiplex board

€ 0.1 + See step 16


28 DESCRIPTION Now make the conductor parts of the support with the topie milling machine. You can use a CLS slat for this, if you first sand it to the right dimensions.


5min.

Topie milling machine

CLS

none

€ 0.25


29 DESCRIPTION Saw the conductors to the right length. Finish the sides with formica. But keep the two outer sides open (see picture).

No

15min.

Contact glue, spray gun

none

none

See step 16


30 DESCRIPTION Screw them onto the supporting board. And finish the last side with formica. Also finish the upper sides of the piece with formica.

No

5min.

Contact glue, spray gun, drill

none

none

€ 0.05 + See step 16


31 DESCRIPTION Mill the supporting triangles out of Volkern with the CNC woodworking machine. Then correct the rounded edges of the upper taps with a file.


53 sec. (milling only)

CNC woodworking machine, file

none

none

€ 0.96


32 DESCRIPTION Fix the hinges onto the triangles with the rivets. Then fix them onto the supporting board with screws (3 x 16mm).


5min.

Hamer, drill

none

none

Rivets: € 1.75, Hinges: €8


33 DESCRIPTION To finish the part you can glue a piece of left over volkern between the hinges, so that when the triangles are opened they cannot exceed a 90° angle.

No

5min.

TEC7

none

none

€ 0


RESULT When all the work is done, the support should look like this image.


34 DESCRIPTION Now cover a multiplex with formica. Then mill out the turning board with a CNC woodworking machine.


3min. 24 sec. (only milling)

CNC woodworking machine, contact glue, spray gunnone

none

€ 3.68


35 DESCRIPTION Finish the other side with formica (cut out the form with a hand milling machine). Attach the parts of the swallow’s tail made earlier with srews. Embed the heads of the srews into the volkern and finish with metal plastic.


1h

Contact glue, spray gun, metal plastic, drill

none

none

€ 0.1


36 DESCRIPTION Make the locking part with Afzelia wood. Saw the two parts, drill the hole with the drill press and make it open with the circular saw. Then attach the two pieces together with the standard hinge. Use 3 x 16mm screws.


0.5h

Drill press, circular saw, drill

Hinge 50 x 20mm

none

€ 1


37 DESCRIPTION Paint the two Afzelia parts black. Attach the standard lock on the other side of the hinge. Use 3 x 16mm inox screws. Make sure the lock keeps the two parts tight together.


0.5h

Drill press, circular saw, drill

Hinge 50 x 20mm

none

€ 0.5 + See step 5


38 DESCRIPTION Drill 2 holes trough the bottom piece of the lock system. Do this under an angle, so that you can attach this piece onto the turning board with screws. It’s advised to also glue the pieces together. When the glue is still wet, you screw the pieces tight.

No

15min.

Wood glue, Drill press, drill

none

none

€ 0.1


39 DESCRIPTION Now finalize the part by adding an extra support under the locking system. Afterwards you paint the whole thing black. Cover the screws with metal plastic.


10min.

Drill, Metal Plastic, Black spray paint (mat)

none

none

€ 0.05 + See step 5


RESULT In the end the turning board should look like this.


40 DESCRIPTION Now we make a bag to put all the parts in for transportation. Start by cutting out the pieces of skai you need. For the outer bag you need: a piece of 1100 x 580mm and two pieces of 500 x 200mm. For the inner bag you need a piece of 930 x 580mm and two pieces of 420 x 100mm.

No

10min.

Scissors

Skai

none

€ 20


41 DESCRIPTION Now stitch two bags. One with the side pieces of 500 x 200mm and one with the side pieces of 420 x 100mm. HINT: Start stitching the side at the bottom and work your way up.

No

1h.

Scissors, Sewing machine

none

none

€ 5


42 DESCRIPTION Make a clean edge on both bags by stitching the borders double.

No

15min.

Sewing machine

none

none

€ 2


43 DESCRIPTION Now stitch the smaller bag onto the bigger bag (when they are inside out). Afterwards turn them back to normal. You now should have the smaller bag inside of the bigger bag.

No

20 min.

Sewing machine

none

none

€ 0


44 DESCRIPTION Now we make a flap to close the bag. Stitch 3 borders double of a piece of 500 x 600mm. Afterwards you can stitch the side you didn’t stitch double, onto the inner side of the big bag.

No

15min.

Sewing machine

none

none

€ 0


45 DESCRIPTION We now glue some velcro onto the bag. The first side about 120mm from the top, the other side at the end of the flap.

No

5min.

Textile glue

Velcro

none

€ 2.75


RESULT The bag should look something like this.


DESCRIPTION You can gather all pieces in the bag for easy transport.


TECHNICAL ADDENDUM



DESCRIPTION -All CNC work was done with a Holzher ECO MASTER 2710 340- The drawings for the CNC pieces were made in Twincam 32. If you want to use the files, please contact somebody of the team. (last slide)

MACHINERY

DESCRIPTION - All equipment you need can be bought in a regular do-it-yourself store.

TO BUY

0

PARTS1. Platform2. Handle3. Conductor right4. Conductor left5. Support6. Turning board

Assembly

Platform

1

Handle

2PARTS2.1 Adjusted bike pedal2.2 Grip2.3 Gardena connection piece

Adjusted bike pedal

2.1

Grip

2.2

Conductor right

3PARTS3.1 Conductor3.2 Hook (x2)3.3 Screws ( 3 x 25 , inox) (x4)

Conductor

3.1

Hook

3.2

DESCRIPTIONThis is the mirror image of the right conductor. The only thing that is different is the way the two main beams are attached to each other. The beam with the hooks mounted on is now placed on the left side of the beam with the conducting slot in.

Conductor left

4

Support

5PARTS5.1 Slide5.2 Supporting triangle (x2)5.3 Standard hinge (62mm) (x4)5.4 Standard closet door handle5.5 Screws (3 x 16, inox) (x12)5.6 Rivets (3.2 x 9) (x12)

Supporting triangle

5.2

Turning board

6PARTS6.1 Height setting board6.2 Lock6.3 Standard locking system6.4 Standard hinge (50mm)6.5 Screws ( 3 x 16, inox) (x 10)

Height setting board

6.1

Lock

6.2

TEAM CONTACTS



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[email protected]


Transportrollator2012 montageplan7

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