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Picture of Reproducible Wooden Bike

The idea of this project is to make a wooden bike that you can download and assemble like an IKEA chair. There is already a lot of wooden bikes on the web but if you are not a professional woodworker or you don't want to spend month refining the parts until they would fit together, then the result will not look like the wooden bikes in design magazines...

It took me 7 days to make this bike (without the design) but I never used a CNC router or a hand router before. In Fablab Moscow we have all these machines and I was looking forward to having an opportunity to use it. So now if you wand yours, find a place with a CNC router (fablab or makerspace), cut the parts according to the files, cut also some lumbers and assemble it.

Step 1: Tools and Material

Tools

  • CNC router
  • Hand router (25mm ball end mill and chamfer or rayon mill)
  • Jigsaw
  • Pressdrill
  • Laser cutter (optional)
  • Chisel 12mm

Material

  • Plywood (15 and 18 mm)
  • Lumber ( 40 x 20 mm: 200, 480, 490, 556, 556, 620, 620 mm) and (30 x 20 mm: 500, 500, 400, 400 mm)
  • Cylindric lumber, diameter: 28mm length: 260
  • Aluminum 5mm 20 x 40 mm
  • Fork bearings
  • Pedals with bearings and axle length: 68 mm diameter: 34mm
  • HTD 8M 1440 belt
  • Tire tubular 22mm
  • Wheels axle and bearings length: 140mm
  • M4 screws and bolt (40, 50, 70 mm)
  • 5 times M6 x 100
xred112 months ago
Is there a breaking system? Is the rear hub a coasting hub or do the pedals keep moving with the rear wheel?
AdrienR (author)  xred112 months ago
Now I don't have any breaks :(
The pedals keep moving with the rear wheel so I can slow down by pushing backwards. It is not effective like a break but for testing it is ok. I will figure out how to add at least a front break.
BilB42 months ago
Looks great and looks like it uses enough metal not to fall apart in the first hour (though it looks like the belt might fall off the side of the gear pretty easily). I look forward to more updates on this - I would like to make this if it goes through a couple more iterations. How is it to actually ride?

EDIT: Oops, I see in one of the pics you've aalready dded a guard to stop the belt falling off the side.
AdrienR (author)  BilB42 months ago
Yes you are right in the first picture I had no guards. Now I have a guard on one side of the front pulley and both side on the rear for space reasons. It seems to work.
As I said the first ride was good but flexible so I am now doubling the top lumber (40 x 40) and when I am happy with the result I will glue everything and coat with epoxy or lacquer. This would probably add even more rigidity.
gzank62 months ago
perhaps the coolest thing I've seen on here. Very impressive would also like to know its weight, and when you can ship me one : ).
AdrienR (author)  gzank62 months ago
Thank you very much!
The weight is around 13kg. It was 12.7 but I am doubling the top tube (horizontal lumber) to increase rigidity. What weights are essentially the plywood parts so doubling the lumber has not a significant impact on the weight. (using 40 x 40 instead of 20 x 40). If you want I can ship you this one after coating :)
diymontreal2 months ago
Wow! This is a very impressive design and build! I have been wanting to get a CNC and now I want one even more just to test this out.
I'm not sure I understand how you made the wheels concave to fit the tires, can you please explain more?
Merci et bravo Adrien!
AdrienR (author)  diymontreal2 months ago
Thank you!
I used a hand router with a half ball mill (cf. image). I first though to make a support for milling the wheel radially but finally it was simpler to mill the slot axially with a wooden guide screwed to the router (cf. 2nd image in step 8). The first image shows the mill type I used and the second image shows the process. I used the mill (that normally should be used vertically) from the side.
fraise-a-gorge-hm-kwo.jpgIMG_3594.JPG
sawdustagain2 months ago
Fascinating project! Please tell us how much it weighs.
AdrienR (author)  sawdustagain2 months ago
Thank you
12.5 kg
Kink Jarfold2 months ago
Well, I'm super impressed wth your skills.
AdrienR (author)  Kink Jarfold2 months ago
Thanks