Handmade Wooden Bicycle
Introduction: Handmade Wooden Bicycle
CONTEXT
College had just started and amidst the madness of timetables and classes, I was searching for ideas for the woodworking class. That's when I found a jazzy bicycle picture on Facebook. At first my carpentry teacher refused to take on such a complex project but soon enough he gave in to my naïve enthusiasm. We quickly realized that recreating an identical model in wood needed a different design approach than a typical bicycle made from steel, aluminium and carbon fibre. We took this into consideration while making the preliminary sketches of various parts that would someday be crafted and put together to roll smoothly.
Step 1: Preparation
Since we lacked the expertise of a cycle mechanic, the first and most obvious thing to do was to learn everything about a typical bicycle. I took a week-long workshop at a local cycle store where I stripped an old cycle it to its essentials and examined the scattered fragments.
All the different bearings were carefully noted as well as the functioning of the axles, the bottom bracket, the crankset and the chainset. After having repainted the frame, every tiny washer and bearing were assembled in the reverse order of dismantling to resurrect the old cycle with a new touch of life.
Step 2: Limitations and Final Design
Back in the woodworking workshop we studied the various tools available for use and their limitations. The Lathe for example could hold a maximum diameter of 11”. Furthermore, the availability of primarily red cedar (used in guitars, pianos, and other instruments) meant that it would not be ideal for crafting minute artistic details nor would slim pieces be very sturdy.
Our final design was no longer a full-sized wooden bicycle, but a smaller one, ideal for children between the ages of 5 and 9. However, provided you have a larger lathe, you can go ahead and make a full sized one too!
Step 3: Material Needed
Most of the machines and tools used can be easily substituted for more sophisticated ones or more elementary ones. None of the machines and tools were automatic or programmable in our workshop. This added a hand-made element to it!
Machines:
* Lathe
* Drill Press
* Drilling Machine
* Sander
* Jigsaw
* Electric Plane and Hand Plane
* Chisels and Hammers
* Files and Rasps
Materials:
* Thermocol (from packaging)
* Red Cedar
* PVC pipe (discarded)
* Cloth
* Sandpapers
* Mild Steel rods/pipes
* Wood glue
* Araldite
* Sealer
* Polish
* Thinner
* Wax
Step 4: Prototype
A full-scale model was first made in thermocol to grasp the challenges in our design. We used a chainset consisting of a freewheel, a sprocket and a chain attached to a shaft made from PVC pipe. 668
It also gave us the opportunity to reinterpret the concepts from the bicycle workshop and apply them to the wooden context. Several factors still remained uncertain regarding the nature of the axles, the shafts and the bearings.
Step 5: The Beginning
We started the woodworking with the largest pieces first. We carved out the wheels, then the three parts of the frame followed by the front fork and lastly, the sprockets and the pedals. The design of some of these parts evolved organically over the period to accommodate the uncertainties. The wheels and the rear forks were formed by glueing two pieces back to back in a way such that their grain runs criss-cross. Since wood breaks more easily along the grain, this additional piece drastically increases its strength. We could have easily used plywood instead since it follows the same concept, but we wanted to work and remain inspired by the natural qualities of the red cedar.
Step 6: Joinery and Metal
Once most of the pieces were ready we got down to exploring the joinery between the wooden components. We also realized that some use of metal will be inevitable in the form of axles, bearings and shafts. These too were made at our workshop. Apart from ball bearings and washers we did not purchase any other parts. Even the bolts were custom made by using taps and threads. You can plan the axle ends differently so that you don't have to custom make too many small parts.
Wooden Joinery
Our preferred method of joinery was a Mortise and Tenon Joint. We also used biscuit Joints to piece together the main frame with the the rear fork.
Ball Bearing
12mm inner Dia needle-racer bearings were perfect for our use because of their elegant and compact look. You can substitute these for any other type of ball bearings that fit your size. 56