GENERAL DISCLAMER! THIS THREAD IS IN METRIC (M)!
First post here so let me start with a brief presentation!
For as long as i can remember i have been sketching on wild projects.
This has been in the range of personal submarines to single-seated aircrafts and many sizes and models inbetween.
My main problem isnt the creative side, but that finishing 20%, or even getting a project of the sketching stage and onto a build stage.
But resently ive been bitten by the bike bug, i just gotta get my hands on a recumbent swb bike!
And to make a long story short, since i cant afford to buy one, its time to build one!
I know that two guys can spot twice the amount of stupidity in a project, so im hoping to get this darn close to perfect with some input from all you guys and gals!
And as i should have mentioned, im from sweden so please apologize any language errors on my behalf :P
Now to the project!
A short wheel base recumbent bike built out of plywood, sheets are cut to shape and then glued together to form a 3 or 4 sheets thick laminate that is the main frame.
Donor bike (26"fullsusp mountainbike) provides rear fork, front fork and stearing tube aswell as bottom bracket with pedal assembly.
Rear fork is bolted directly onto the wood frame, stearing tube is glued into the laminate with a added weight distributing plate under the frame.
If you would google "recumbent plywood mistress" (http://carbonbent.bravehost.com/
) you will find a guy that built pretty much exactly what im after.
Some differences do exist, he´s using carbonfibre as outer layer, witch i will not, and i will be using equally large wheels (his front wheel is smaller).
Now, the thing is that my experience with wood is very limited so i do need some guidance on material selection and suggestions on bonding agents.
I dont know the english terms for the types of plywood they have at my local lumberyard but i figure i shouldnt use any of that waterproofed (painted) plywood?
There are two other types, a general construction plywood for walls and stuff, or marine plywood (same dimensions, twice the price).
Do i need marine grade or can i save a buck?
Im planning on preparing the finished frame surface with paint or similar (suggestions??), but probably wont use any type of fibers on the initial build.
The current sketch dimensions are pretty rough, but frame cross section would be about 60mm width and 100mm height, tapering to about 70mm at bottom bracket and 170 around rear fork fix point.
Cross section is square with about R10mm rounded edges.
Pockets are parallel with outer contour, about 50-100mm in length and about 20mm corner radius.)
How thick would the sides/corners around the cross section be over the weight reducing pockets?
im also planning on purchasing a router, the handheld powertool, to cut out weight saving pockets from the center layers aswell as fillet the external corners on the finished frame.
Is this possible with any generic router or do i need to buy something specific for the job?
Suggestions on mill-bit types and sizes would also be appreciated!
So in short:
I need help selecting correct plywood, glue and material thickness on the construction.
I also need more info about routers in general and more specifics for these type of applications.
Hints, ideas, suggestions or just thumbs up are always apreciated!
I want to post this project build blog somewhere i can stuff it with photos and stuff, is that possible here? :)
..unfortunately i cannot show you anything yet, the current sketch, pencil on cardboard, doesnt show on any photos...
I belive in sharing of knowledge so the plans for this project will be freely available when its deemed safe (enough
Thank you for your patience!
Live long and proper!